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Old 03-14-2018, 03:27 PM   #5
xkalelx
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Welding inspector/educator chiming in. Could you clean the dust and grit from that area and take another picture? An easy test to see if the spot weld has failed is to stick a flat head screwdriver in the gap and pry up up in easy, maybe 10ft/lbs. if it separates easily and the gap gets bigger, then you have a failed spot weld. I wouldn't even consider welding it until you verify that first.

Spots welds are nearly 99.9999% perfect from a top tier mfg like Subaru and are not easily prone to failure. The machines and quality control they use for this operation are pretty failsafe. So much so that most failures are in the base material NEAR a spot weld because the weld will be stronger than the base material around it.
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