Weld stud

A weld stud comprising:

• a cylindrical body elongated in a longitudinal direction and having a first peripheral dimension;
• at least three separate threads longitudinally extending from substantially one end of the body to the opposite end of the body in a substantially parallel spiraling manner, each of the threads being spaced apart from each other and each of the threads spiraling around the body less than 360.degree.;
• a base having a peripheral second dimension larger than the first dimension;
• a welding pedestal projecting from the base opposite the body, the pedestal being substantially coaxially aligned with the base, the pedestal having a third peripheral dimension smaller than the second dimension;
• a head coaxially aligned with the body and having a fourth peripheral dimension;
• and
• a neck joining the head to the body, the neck having a fifth peripheral dimension less than the first and fourth dimensions.

An automotive vehicle electrical grounding system comprising:

• a metal body panel of the vehicle;
• a metal stud having a first segment attached to the panel, a second segment longitudinally extending from the first segment and a third segment longitudinally extending from the second segment opposite the first segment;
• the second segment being transversely larger than either the first and third segments;
• the third segment being longitudinally elongated larger than either the first and second segments;
• the stud further having a neck longitudinally extending from the third segment and a head longitudinally extending from the neck opposite the third segment, the head having a transverse dimension smaller than the second segment and the neck having a transverse dimension smaller than either the head and the third segment;
• a plurality of spaced apart threads projecting from the third segment and each of the threads substantially extending in a longitudinally spiraling manner from adjacent the neck to adjacent the second segment;
• and
• an electrically conductive path provided between the third segment of the stud and the panel.

A weld stud cap comprising:

• a longitudinally elongated cylindrical portion;
• an inwardly barbed portion;
• a living hinge portion flexibly connecting the cylindrical portion to the barbed portion;
• a head portion attached to the barbed portion substantially opposite the living hinge portion, the head portion including a transversely oriented wall;
• and
• at least one elongated finger projecting from the head portion.

A method of assembling a weld stud to an automotive vehicle panel to create an electrically grounded path between the stud and the panel, the stud having threads and the cap having barbs, the method comprising:

• (a) forming multiple spaced apart, spiral threads on the stud;
• (b) welding the stud to the panel;
• (c) pushing a protective cap over a threaded segment of the stud to deter a coating from contaminating the threads;
• (d) flexing the cap to at least partially disengage barbs of the cap with an undercut of the stud;
• and
• (e) substantially linearly pulling the cap off of the stud to expose the threads of the stud for a subsequent electrical connection.