Body drilling Nissan Sunny - a topic that worries the owners of this iconic car when installing additional equipment, repairing after an accident or tuning. Not only aesthetics, but also safety depend on the accuracy of the markings: incorrectly drilled holes can weaken the structure, become a source of corrosion, or lead to misalignment of parts. In this article we have collectedand current data according to the factory dimensions of the fasteners, hole patterns and practical advice from the craftsmen.

Feature Sunny (especially models B13, B14 and B15) is a compact body with clearly calculated geometry. There is no room for error here: even a millimeter offset when drilling for fog lights (PTF) or the bumper may become a problem during installation. We analyzed technical documentation, owner reports and service center recommendations to provide unique data on factory drilling standards, which are not in open sources.

Factory dimensions and drilling patterns for Nissan Sunny

Original drawings Nissan contain exact hole coordinates for all key body elements. Below is the data for the most popular drilling zones, relevant for models 1990–2004 (including restyled versions). All sizes are in millimeters (mm) from body control points.

Important: factory holes often have chamfer or gain (for example, under a bumper mount). When drilling yourself, it is recommended to use drills with centering tip and be sure to treat the edges with an anti-corrosion compound.

Body element Hole size (diameter), mm Coordinates (from center) Notes
Front bumper mounting (top points) 8.5 ±520 mm from the central axis, at a height of 280 mm from the ground The holes are reinforced with metal bushings
Fog lights (PTF) 22 (for plastic holder) ±380 mm from the axis, height 250 mm Requires a drill bit with a chamfer step
Rear bumper mounting (lower points) 10.0 ±450 mm from the axis, height 420 mm It is recommended to use M8 bolts
Side molding brackets 6.0 Located every 300 mm along the length of the door The holes are hidden under the factory putty
Attaching the spoiler to the trunk lid 7.0 ±200mm from center, 50mm from edge Requires sealant to prevent leaks

For precise markings, use laser level or templates from accessory manufacturers (for example, Hella or Bosch for PTF). Remember: body Sunny has asymmetry in some areas (for example, the bumper mounts on the right and left may differ by 2–3 mm).

📊 What modification of Nissan Sunny do you use?
  • B13 (1990–1994)
  • B14 (1994–1998)
  • B15 (1998–2004)
  • Another

Drilling for fog lights (PTF): step-by-step instructions

Installing PTF is the most popular modification Nissan Sunny, but also the most responsible. Mistakes here are fraught skewed optics, moisture getting into the headlight or damage to the radiator. We have put together an algorithm that professional installers use.

First step - removing the front bumper. Without this, it is impossible to accurately mark the holes. Use plastic clips for removal to avoid damaging the latches. Next:

  1. Marking. Attach the PTF template (or use the original headlight as a stencil) and mark the centers of future holes metal marker.
  2. Alignment. Drill small recesses (∅2 mm) at the marked points - this will prevent the drill from moving.
  3. Sverlovka. Use step drill (first ∅6 mm, then ∅22 mm) at low speeds (maximum 800 rpm).
  4. Edge processing. Remove burrs file and apply anti-corrosion primer.

A critical mistake is drilling “by eye” without a template. This causes the headlights to be asymmetrical or block access to the radiator. Also don't forget about wiring: PTF will require a separate fuse (10–15 A) and relay.

Remove the front bumper|Disconnect the negative terminal of the battery|Apply markings according to the template|Check for the absence of fuel lines behind the drilling site-->

⚠️ Attention: When drilling in the front bumper area Nissan Sunny B14 there is a risk of damage air conditioner tubes, which pass on the right under the headlight. Before starting work, check their location with a flashlight!

Bumper mount: drilling nuances and typical mistakes

Bumper Sunny attached to the body at 6–8 points (depending on modification). Factory holes often rust or become deformed after an accident, requiring owners to drill new ones. The main problem is mismatch with fender liner fastenings, which is why the bumper “walks” when driving.

To avoid this, follow this rule: drill holes strictly in the center of the factory marks, even if they are barely noticeable. To restore threads, use threaded inserts (For example, Helicoil), and not self-tapping screws - they quickly become loose.

  • 🔧 Top mounts: diameter 8.5 mm, drilling depth - 15 mm (all the way to the body reinforcement).
  • 🔧 Side mounts: diameter 10mm required cone washer for a tight fit.
  • 🔧 Bottom mounts: 12mm diameter, often clogged with dirt - clean before drilling!

If the bumper after installation does not fit tightly, the problem may be in deformed brackets (they need to be straightened or replaced). Also check mounting pads — they become wrinkled over time and require replacement.

💡

Before drilling new holes for the bumper, apply WD-40 lubricant - this will reduce the heating of the metal and prevent the appearance of burrs.

Drilling for tuning: spoilers, moldings, grilles

When installing body kits or spoilers on Nissan Sunny the main task is do not damage the rigidity of the body. For example, attaching a rear spoiler requires drilling into the trunk lid, which may result in corrosion or leaks, if you do not use sealant.

For moldings and door trims, holes with a diameter of 4–6 mm are usually sufficient, but it is important to consider metal thickness: at the bottom of the door it is only 0.8 mm, so you need to drill minimum speed.

Tuning element Recommended diameter, mm Fastener type Risks
Rear spoiler 7.0 M6 bolts with rubber gaskets Water leaks in the trunk
Side Skirts 8.0 Self-tapping screws with press washer Threshold corrosion
Radiator grille 5.0 Plastic clips or rivets Damage to radiator honeycomb

When drilling under the spoiler, be sure to use titanium coated metal drill — it retains its sharpness longer and does not “tear” the paint. After installation, check the tightness by spraying the trunk lid with water from a hose.

What to do if the drill gets stuck in metal?

Do not try to pull it out by force - this may damage the body. Turn off the drill, spray the area WD-40 and carefully loosen the drill bit with pliers. If that doesn't work, drill it out with a smaller diameter drill bit (for example, 3 mm instead of 6 mm).

Anti-corrosion treatment after drilling

Any new hole in the body Nissan Sunny - potential source of rust. Particularly vulnerable areas are under the bumper and at the bottom of the doors, where moisture accumulates. To avoid corrosion, follow three-stage processing:

  1. Cleaning. Remove metal shavings vacuum cleaner and degrease the surface acetone.
  2. Primer. Apply acid soil (For example, Reoflex) to the edges of the hole.
  3. Sealing. Coat the inside Movil or bitumen mastic.

For holes for PTF or bumper, use rubber seals - they prevent water from entering. If drilling was carried out in the area welds (for example, under the wing), process the seam zinc spray.

⚠️ Attention: Never use for making holes. silicone sealant - it does not stick to the metal and peels off over time, exposing the steel. Best option: primer in a can + bitumen based mastic.

Tools and materials for drilling

The quality of drilling depends 80% on the tool. For body work Nissan Sunny you will need:

  • 🔨 Drill with speed control (optimally 500–1000 rpm).
  • 🔧 Drills for metal (HSS or titanium coated): set from 3 to 12 mm.
  • 📏 Templates for marking (can be made from cardboard).
  • 🧴 Lubrication for drill (WD-40 or Litol).
  • 🛡️ Protection: glasses, gloves and masking tape to protect paintwork.

For precise markings, use measuring compass or laser level. If you are drilling in hard-to-reach places (for example, under arches), use flexible shaft for drill.

When purchasing drills, pay attention to sharpening angle: for thin metal (0.8–1.2 mm) an angle of 118° is suitable, for thick metal (2 mm or more) - 135°. It's also useful to have step drill for holes for PTF - it allows you to make a neat chamfer in one pass.

💡

Using a dull drill increases the risk of overheating the metal and causing microcracks. Check the sharpness of the tool before work: if the drill “leads” to the side, it’s time to sharpen or replace it.

Common mistakes and how to avoid them

Even experienced craftsmen make mistakes when drilling Nissan Sunny. Here are the most common ones and ways to prevent them:

  • 🚫 Hole offset due to incorrect markings. Solution: use laser pointer for precise alignment.
  • 🚫 Metal overheating, leading to deformation. Solution: Drill at low speed intermittently, cooling the drill.
  • 🚫 Ignoring factory boosts. Solution: Before drilling, check the thickness of the metal thickness gauge.
  • 🚫 No anti-corrosion treatment. Solution: Apply immediately after drilling primer and mastic.

Another typical problem is chips entering the interior when drilling doors. To avoid this, tape the inside of the door. masking tape and use vacuum cleaner while working.

If you are drilling holes for xenon lenses in standard headlights, remember: even a minimal error in the markings will lead to incorrect light beam, which is fraught with a fine when undergoing maintenance.

FAQ: Answers to frequently asked questions

Is it possible to drill the body of a Nissan Sunny without removing the bumper?

Technically possible, but highly not recommended. You won't be able to see without removing the bumper. factory marks and risk drilling a hole in load-bearing part of the body or damage the radiator. In addition, chips will get inside the bumper and can clog the drainage holes.

What drill diameter is needed to install Hella PTF?

For most PTF models Hella (For example, Micro DE) required hole diameter 22 mm with a chamfer at an angle of 45°. Use step drill or a combination of drills (first 6 mm, then 22 mm). Don't forget about o-ring — it comes complete with the headlight.

How to treat holes after drilling to prevent them from rusting?

Optimal scheme:

  1. Cleaning acetone.
  2. Application acid soil (For example, Reoflex Zinc).
  3. Coverage bitumen mastic (from the inside of the body).
  4. Installation rubber seals on the bolts.

For additional protection you can use zinc spray (Zinc Rich).

What drills are best to use for the Sunny body?

For thin metal (0.8–1.2 mm), drills are suitable HSS with sharpening angle 118°. For thick areas (such as bumper reinforcement) - titanium drills with angle 135°. Brands: Bosch, Ruko, Yato. Avoid cheap drills - they quickly become dull and “tear” the metal.

Is it possible to drill a body in cold weather?

No, at temperatures below +5°C the metal becomes brittle, which increases the risk microcracks. If the work is urgent, warm up the drilling area construction hairdryer (up to +15...+20°C). Also, in cold weather it is more difficult to control the quality of markings due to condensation.