Weld bonding of aluminium autobody structures offers automotive vehicle manufacturers the opportunity of achieving significant weight reduction, compared to equivalent steel structures. Further, this is achievable using volume production manufacturing methods. This paper considers all key aspects of the weld bonding process, in particular the equipment requirements and the factors that are important in reliably achieving satisfactory structures. Methods of minimising damage to the adhesive bondline and assessment of spot weld quality are discussed. Using experience gained from extensive weld bonding trials, suitable parameters for robust weld bonding are recommended.