The Repair of Vehicle Bodies, Fifth Edition

Cover......Page 1
Contents......Page 8
Foreword......Page 14
Preface......Page 16
Acknowledgements......Page 20
Glossary......Page 24
Abbreviations and symbols......Page 30
Development of the motor car body......Page 34
Creation of a new design from concept to realization......Page 47
Methods of construction......Page 65
Basic body construction......Page 70
Identification of major body pressings......Page 76
Vehicle type approval......Page 85
Questions......Page 90
Personal safety and health practices......Page 92
Fire precautions......Page 98
Safety signs in the workshop......Page 103
General safety precautions in the workshop......Page 105
RIDDOR......Page 108
Maintain the health, safety and security of the work environment......Page 109
Questions......Page 117
Hammers......Page 118
Hand Dollies......Page 121
Body spoons......Page 122
Body files......Page 123
Hand snips......Page 124
Specialist panel beating tools......Page 125
Recommended basic toolkits for panel beaters......Page 130
Hammers and mallets......Page 131
Sheet metal bench stakes......Page 133
Cutting tools......Page 135
Bending and swaging tools......Page 137
General-purpose assembly and dismantling tools......Page 138
Power tools used in body repair work......Page 142
Metal cutting shears and nibblers......Page 143
Power drills......Page 146
Sanding machines......Page 147
Other power tools......Page 150
Dust extraction for power tools......Page 152
Questions......Page 154
Manufacture of steel coil and sheet for the automobile industry......Page 155
Specifications of steels used in the automobile industry......Page 156
Carbon steel......Page 157
Alloy steels......Page 163
Stainless steel......Page 165
Aluminium......Page 166
Aluminium alloys......Page 167
Rubber......Page 174
Sealers......Page 175
Sound deadening, thermal insulating and undersealing materials......Page 177
Interior furnishings......Page 179
Plastics......Page 181
Plastics repair......Page 186
Safety glass......Page 189
Questions......Page 191
Properties of metals......Page 193
Heat treatment of metals and metal alloys......Page 196
How metal is formed to provide strength......Page 200
Cutting machines......Page 202
Bending theory......Page 204
Bending machines......Page 205
Rolling machines......Page 206
Wheeling machines......Page 208
Swaging machines......Page 209
Brake presses......Page 211
Forming and drawing......Page 213
Questions......Page 215
Marking out......Page 217
Basic marking-out and measuring instruments......Page 218
Precision marking-out and measuring instruments......Page 225
Questions......Page 229
Solid rivets......Page 230
Bifurcated, tubular and semitubular rivets......Page 232
Blind rivets......Page 233
Structural fasteners......Page 241
Screws and bolts......Page 244
Fastening devices......Page 251
Adhesives......Page 256
Questions......Page 266
Comparison of fusion and non-fusion jointing processes......Page 268
Soft soldering......Page 269
Hard soldering......Page 273
Questions......Page 280
Development of gas welding......Page 281
Systems of gas welding......Page 282
Oxy-acetylene welding equipment......Page 283
Definitions of welding terms......Page 289
Flame control and types of flame......Page 290
Methods of welding......Page 292
Edge preparation and types of joint......Page 293
Welding various metals......Page 296
Gas cutting......Page 297
Gases: characteristics and colour coding......Page 299
Safety measures......Page 301
Plasma arc cutting......Page 304
Questions......Page 308
Resistance welding in car body manufacture......Page 310
Resistance spot welding......Page 312
Resistance seam welding......Page 313
Resistance butt welding......Page 314
Resistance spot welding of high-strength steels......Page 315
ARO Spotrite Pulsa resistance welding system......Page 320
Single-sided spot welding......Page 323
Questions......Page 326
Principles of manual metal arc welding......Page 327
Metal arc welding equipment......Page 328
Electrodes used in welding: BS coding......Page 331
Arc welding positions......Page 334
Essential factors of arc welding......Page 335
Technique of welding......Page 339
Safety precautions for the welder......Page 340
Questions......Page 341
Development of gas shielded arc welding......Page 342
Gases used for shielded arc processes......Page 343
TIG welding......Page 345
TIG spot welding......Page 347
Equipment used in TIG welding......Page 348
TIG welding techniques......Page 351
MIG/MAG welding......Page 352
MIG/MAG spot/plug welding......Page 353
Equipment used in MIG/MAG welding......Page 354
MIG/MAG welding techniques......Page 360
Applications of MIG/MAG welding in vehicle body construction......Page 364
Applications of MIG/MAG welding in body repair work......Page 365
Welding stress and distortion in the MIG/MAG process......Page 368
Weld testing and inspection......Page 372
Equipment maintenance and safety......Page 373
Questions......Page 374
Shaping metal by hand......Page 375
General guide to the fabrication of hand-made panels......Page 383
Edge stiffening of sheet metal......Page 386
Techniques of damage rectification......Page 389
Hammering techniques......Page 391
Filing......Page 395
Sanding or disc grinding......Page 396
Hot shrinking......Page 397
Cold shrinking......Page 399
Body soldering......Page 400
Chemically hardening fillers (plastic fillers)......Page 401
Body jack (hydraulic)......Page 405
Application of the body jack......Page 408
Care and maintenance of body jack......Page 412
Repair of component motor body panels......Page 413
Aluminium panel repair......Page 423
Body electrical and electronic systems......Page 431
Questions......Page 436
Damage classification and assessment......Page 438
Pulling, alignment and repair systems used on major accident damage......Page 439
Alignment of the modern integral body......Page 471
Major repair techniques......Page 482
Estimating and costing......Page 515
Questions......Page 532
Initial planning......Page 534
Planning the areas of the workshop......Page 536
Bodyshop heating......Page 542
Bodyshop lighting......Page 543
Essential equipment for the bodyshop......Page 545
Bodyshops and legal requirements......Page 548
Quality Management for the bodyshop: BS EN ISO 9001–2000......Page 561
Questions......Page 563
Development of reinforced composite materials......Page 565
Basic principles of reinforced composite materials......Page 566
Manufacture of reinforced composite materials......Page 567
Types of reinforcing material......Page 569
Resins used in reinforced composite materials......Page 572
Moulding techniques for reinforced composite laminates......Page 575
Designing reinforced composite materials for strength......Page 580
Body production in reinforced composite plastic (Lotus)......Page 593
Repair of reinforced composite bodies......Page 595
Common faults in moulded laminates......Page 600
Safety precautions......Page 605
Questions......Page 606
History of automotive finishing......Page 607
Glossary of terms used in spray painting......Page 609
Types of paint......Page 610
Materials used in refinishing......Page 612
Spray painting equipment......Page 615
Types of spray gun......Page 617
Basic parts of a standard spray gun......Page 621
Spray gun maintenance and cleaning......Page 623
Spray gun motion study......Page 625
Spraying defects......Page 628
Sanding and polishing machines......Page 631
Preparation of a motor vehicle for repainting......Page 633
Finishing and refinishing processes......Page 635
Burnishing, polishing and final detail work......Page 647
Rust-proofing......Page 649
Comparison of hot and cold spraying......Page 653
Movement of vehicle in the paint shop......Page 654
Common spray painting defects......Page 655
Colour mixing and matching......Page 657
Questions......Page 658
Index......Page 660