Nissan Sunny FB15 is a legendary Japanese sedan that is still in demand among car enthusiasts due to its reliability and unpretentiousness. However, when repairing or tuning a body, many are faced with the need for drilling - be it installing a bumper from another modification, installing crankcase protection, or attaching additional equipment. In this article we will analyze in detail standard drilling patterns for FB15, suitable drills, as well as nuances that will help you avoid mistakes when working with body metal.

Feature Sunny FB15 (1990–1994) is that its body, despite the simplicity of its design, has a number of “secret” attachment points that are not indicated in the official documentation. For example, when installing the front bumper from Nissan Pulsar N14 New holes must be drilled, but their location depends on the year of manufacture and configuration. We have collected current size data, including rare modifications with factory holes for spoilers or fog lights.

Standard body hole sizes Nissan Sunny FB15

Basic attachment points on FB15 are unified for most parts, but there are exceptions. For example, the holes for the front bumper have a diameter 8.5 mm, and for the rear - 10 mm. It is important to consider that Japanese manufacturers often use metric thread (For example, M6 or M8), but in some cases - inch (1/4"), especially for additional equipment.

Below is a table with the most popular sizes for typical jobs:

Part/element Hole diameter (mm) carving Notes
Front bumper (standard) 8.5 M6 For attachment to side members
Rear bumper 10.0 M8 Reinforced load points
Fog lights (OEM) 6.0 M5 Only for factory equipped models
Crankcase protection 8.0 M6 It is recommended to use self-tapping screws with a press washer
Attaching the spoiler to the trunk lid 7.0 M5 Requires sealant to prevent corrosion

⚠️ Attention: When drilling under fog lights on models without factory preparation, it is necessary to take into account the location front bumper wiring harness. Incorrect drilling may damage the temperature sensor or ABS connection wires.

📊 What part do you most often drill on a Nissan Sunny?
  • Front bumper
  • Rear bumper
  • Crankcase protection
  • Spoiler
  • Fog lights
  • Other

Drilling patterns for popular modifications

If you are installing non-standard parts, for example, a bumper from Nissan Lucino or Pulsar, you will need to adapt the fastenings. Below are diagrams for the most common cases:

  • 🔧 Front bumper from Pulsar N14: It is necessary to drill 4 additional holes with a diameter 8.5 mm in the spars. Distance from the center of the front wheel to the hole - 420 mm.
  • 🔧 Rear spoiler: 6 holes are drilled for mounting to the trunk lid 7 mm in increments 150 mm from the central axis.
  • 🔧 Crankcase protection: the standard scheme involves 8 points - 4 on each side. Holes for screws M6 must be countersunk for a tight fit.
  • 🔧 Fog lights (universal): if there is no factory preparation, drill at a distance 120 mm from the bottom edge of the bumper and 250 mm from the center of the car.

For precise positioning, use cardboard templates - this will help avoid distortions. For example, when installing a front bumper, first secure it with masking tape, mark the centers of future holes with a pencil, and then drill in stages, starting with a smaller diameter (4–5 mm).

Where can I download official drilling diagrams?

Official diagrams for Nissan Sunny FB15 can be found in the manuals FSM (Factory Service Manual) for model B13 (similar in platform). Look for sections Body Dimensions or Exterior Trim. Resources like Nicoclub.com or JapaneseNostalgicCar.com, where enthusiasts post scans of original documentation.

Selecting drills and tools: what you need for the job

For drilling Nissan Sunny FB15 You will need not only the correct drill diameter, but also the right tool. The car body is made of thick steel 0.8–1.2 mm, so it is important to avoid overheating the metal. Optimal drills:

  • 🛠️ For bumper: step drill 4–10 mm (For example, Ruko 2240) - helps avoid paint chipping.
  • 🛠️ To protect the crankcase: metal drill HSS 8.0mm with titanium coating (for durability).
  • 🛠️ For the spoiler: drill 7.0 mm + countersink for forming countersinks for bolt heads.
  • 🛠️ For fog lights: crown 25 mm (if you need larger holes for the headlights).

⚠️ Attention: When drilling close to welds (for example, in side members), use drills with reduced sharpening angle (118° instead of standard 135°). This will reduce the risk of cracks in the metal. Also be sure to use lubricant (For example, WD-40 or cut soap) to cool the drill.

Don't forget about protection: When working with metal, small chips are formed that can damage the paintwork. Use masking tape around the drilling area and vacuum cleaner for collecting sawdust.

☑️ Checklist before drilling

Done: 0 / 5

The subtleties of drilling: how to avoid corrosion and damage

One of the main consequences of unskilled drilling is corrosion. On Nissan Sunny FB15 This is especially true due to the age of the cars: many bodies already have pockets of rust, and new holes can speed up the process. To avoid this:

  1. Finish the edges of the holes anti-corrosion primer (For example, Body 990) immediately after drilling.
  2. Use zinc plated bolts or stainless steel (A2-70).
  3. Apply sealant (For example, Terostat 922) on threaded connections in contact with the external environment.
  4. To attach plastic parts (bumpers, spoilers), use clips with rubber seals.

Critical nuance: on models FB15 with a galvanized body (rare, but they do occur), drilling without cooling leads to local destruction of the zinc layer. In this case, be sure to use drilling machine with coolant supply (cutting fluid) or at least regularly moisten the drill with kerosene.

If you are drilling holes for fog lights, please note that in the bumper FB15 often hidden plastic stiffeners. Damage to them can lead to stress cracks. Before drilling, shine a flashlight through the bumper - the ribs will be visible in the light.

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For precise drilling at an angle (e.g. for attaching a spoiler), use conductor - a homemade device made of aluminum profile with pre-drilled holes. This ensures perpendicularity and equal spacing.

Common mistakes and how to avoid them

Even experienced craftsmen sometimes make mistakes when drilling Nissan Sunny FB15. Here are the most common ones and how to prevent them:

  • ❌ Drilling by eye: Without marking, the holes are often misaligned. Solution: use laser level or template.
  • ❌ Ignoring a layer of paint: When drilling at high speeds, the paint melts and sticks to the drill. Solution: start at low speed (300–500 rpm) and use a drill with sharp end.
  • ❌ Wrong choice of drill: Too large a diameter causes the hole to "break". Solution: drill in 2 stages (for example, first 5 mm, then 8.5 mm).
  • ❌ Lack of chip protection: metal dust enters the cabin through the ventilation. Solution: seal the ventilation grilles masking tape.

Drilling errors are especially dangerous. spars. For example, if you drill a hole too close to the edge, it will weaken the structure and may lead to deformation in an accident. On FB15 safe distance from the edge of the spar to the center of the hole - not less 25 mm.

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When installing non-standard bumpers, always check compatibility with mounting brackets. For example, a bumper from Nissan Pulsar requires modification of original brackets Sunny — they need to be trimmed with a grinder and strengthened by welding.

Drilling for tuning: spoilers, body kits, grilles

If you are into tuning Nissan Sunny FB15, then drilling is an inevitable stage. For example, to install trunk lid spoiler you will need:

  1. Remove the trunk trim and mark the centers of future holes (usually 4–6 points).
  2. Drill holes with diameter 7 mm and countersink them for countersunk bolts.
  3. Process the edges anticorrosive and apply sealant to the threads.
  4. Install the spoiler using bolts M5 with rubber washers.

For installation body kits (for example, from Nismo) it is often necessary to drill holes in rapids or wheel arches. It is important to consider here:

  • 🚗 Thickness of metal in arches - 1.0–1.2 mm, so drill at low speed.
  • 🚗 To attach body kits, use self-tapping screws with press washer (For example, Din 7504).
  • 🚗 If the body kit is plastic, pre-drill holes in it 0.5 mm morethan in metal to avoid cracks.

⚠️ Attention: When installing radiator grilles (for example, from Nissan Silvia S13) do not drill holes in radiator frame - this will weaken the structure. Instead use stainless steel clamps or attach the grille to the bumper.

FAQ: answers to frequently asked questions

Is it possible to drill spars on FB15 without consequences?

You can drill the side members, but with caution. Main rules:

  • Don't drill any closer 25 mm to the edge of the spar.
  • Use a drill with a diameter no larger than 8.5 mm.
  • After drilling, process the hole primer for metal and sealant.

If you plan to install heavy parts (for example, a winch), it is better to use welded brackets instead of drilling.

Which drill is best for drilling a bumper?

For plastic bumper FB15 optimal:

  • Step drill (For example, Wolfcraft 4525) - for neat holes without chips.
  • Metal drill with a sharpening angle of 90° — if you need to drill metal inserts in the bumper.

Drilling speed: 800–1000 rpm for plastic, 300–500 rpm for metal.

How to avoid corrosion after drilling?

To prevent holes from rusting:

  1. Clean the edge of the hole from any metal shavings.
  2. Apply acid soil (For example, Reoflex).
  3. After drying, cover acrylic primer and paint.
  4. Use bolts with zinc coating or stainless steel.

For additional protection you can apply wax composition (For example, Turtle Wax) on the thread.

Can I use a drill instead of a drill press?

Yes, but with reservations:

  • Use drill with speed control (For example, DeWalt DCD771).
  • Secure the part clampsto avoid vibration.
  • Drill on low speed (up to 500 rpm for metal).

For accuracy use guide bushing or conductor.

Where can I find original drilling diagrams for FB15?

Official diagrams can be found in:

  • FSM (Factory Service Manual) for Nissan Sunny B13 (similar platform).
  • Japanese auctions (For example, Buyee.jp) - sometimes scans of documentation are sold.
  • Forums: Nicoclub.com, JapaneseNostalgicCar.com, Drive2.ru (search by tag #SunnyFB15).

Also useful 3D body models (for example, on GrabCAD), where you can measure the distances between the attachment points.