Volkswagen ID.4: Making a flow-drill screw connection, pre-drilled hole in upper part

• Loosen flow-drill screw connection using socket for flow-drill screws.
• Remove upper part.
• Prepare connections for applying adhesive.
• Clean bonding surface with cleaning solution.
• Apply 2-pack epoxy adhesive to entire area.
• Position new part, and secure it by using socket for flow-drill screws to tighten new screws to 7 Nm.

Making a flow-drill screw connection, no pre-drilled hole in upper part

• Loosen flow-drill screw connection using socket for flow-drill screws.
• Remove upper part.
• Insert hole detectors in the existing FDS threads. Consider offset due to hole detectors: Eventually, perform marking for each area.
• Position new part.
• Use light blows of a rubber-headed hammer to carefully mark the holes in the new part.
• Remove upper part.
• Drill holes with Ø 7 mm in new part.
• Prepare connections for applying adhesive.
• Clean bonding surface with cleaning solution.
• Apply 2-pack epoxy adhesive to entire area.
• Position new part, and secure it by using socket for flow-drill screws to tighten new screws to 7 Nm.

Making a flow-drill screw connection, exchanging upper and lower parts

• Loosen flow-drill screw connection using socket for flow-drill screws.
• Remove both parts.
• Drill holes of 4 mm in diameter through both parts having the same distance to each other as in original joint.
• Remove new parts.
• Expand 4 mm holes in upper part to 7 mm in diameter.
• Prepare connections for applying adhesive.
• Clean bonding surface with cleaning solution.
• Apply 2-pack epoxy adhesive to entire area.
• Position new part, and secure it by using socket for flow-drill screws to tighten new screws to 7 Nm.

Renewing friction-element-welded joints

Friction element welding is used in multi-material body-in-white manufacturing to join ultra-high-strength steel with aluminium components. A distinction is made between standard friction elements and countersunk friction elements.

Overview of riveting attachmentsSurface repair