Why Certain Repairs Can’t Be Done with Plug Welds Anymore

Plug welds were once the go-to solution for attaching replacement panels. But with today’s materials and crash standards, OEMs often prohibit plug welds in favor of more advanced methods.

Why Plug Welds Fall Short

• Too much heat: Creates large heat-affected zones.

• Inconsistent strength: Doesn’t always match factory spot welds.

• Not crash-tested: Automakers test vehicles with spot welds, rivets, or brazing — not plug welds.

What OEMs Require Instead

• Spot welds: Replicate factory conditions.

• MIG brazing (silicon bronze): Lower heat, better corrosion resistance.

• Structural adhesives and rivets: Common in aluminum repairs.

FAQs

Can plug welds ever be used?

• Yes, in certain non-structural areas, but only when OEMs allow it.

Why do shops still use plug welds?

• Some don’t invest in the right equipment.

Is it dangerous?

• In the wrong place, yes. It can compromise crash safety.

Final Thoughts

Plug welds belong to the past. Today’s vehicles require precise, OEM-specified welds for safety. At Solon Collision, we never cut corners with outdated methods.