The repair of vehicle bodies

Cover
Title
Copyright
Dedication
Contents
Preface
1	Car body construction
	Starting out
	Vehicle safety testing
	Elements of vehicle construction
	Vehicle information code plate
	Brief history of the motor vehicle
	Skills and questions
2	Health and safety and the environment
	Personal health and safety procedures
	Fire precautions
	Fire risks in the workshop
	Safety signs in the workshop
	General safety precautions in the workshop
	Electrical hazards
	COSHH
	RIDDOR
	Maintain the health, safety and security of the work environment
	Where identified hazards cannot be removed, appropriate action is taken immediately to minimize risk to own and others’ health and safety
	Skills and questions
3	Hand and power tools
	Hand tools used in body repair work
	Hammers
	Hand dollies
	Body spoons
	Body files
	Hand snips
	Specialist panel beating tools
	Clamps
	Punches
	Edge setters or jogglers
	Sheet metal bench stakes
	Hand grooving tools
	Rivet sets
	Cutting tools
	Bending and swaging tools
	General-purpose assembly and dismantling tools
	Skills and questions
4	Materials used in vehicle bodies
	Skills
	Aluminium
	Rubber
	Sealers
	Sound-deadening, thermal insulating and undersealing materials
	Interior furnishings
	Plastics
	Amorphous and crystalline plastics
	Abbreviations for automotive plastics
	Types of plastics
	Repair procedures
	Painting plastics
	Safety glass
	Skills and questions
5	Metal forming processes
	Properties of metals
	Heat treatment of steel and aluminium
	Machines for sheet metal fabrication
	Cutting machines
	Bending theory
	Bending machines
	Rolling machines
	Forming and drawing
	Sheet metal cutting for press work
	Skills and questions
6	Marking out and measuring
	Marking out
	Manufacture of templates
	Basic marking-out and measuring instruments
	Precision marking-out and measuring instruments
	Micrometer
	Skills and questions
7	Methods of joining
	Solid rivets
	Types of riveted joint
	Blind rivets
	Repetition rivets
	Rivet selection
	Structural fasteners
	Screws and bolts
	Fastening devices
	Adhesives
	Selection of adhesives
	Achieving good results with adhesives
	Adhesives and the automotive industry
	Skills and questions
8	Soft and hard soldering methods
	Comparison of fusion and non-fusion jointing processes
	Soft and hard solders
	Soft soldering
	Hard soldering
	Body leading/body soldering
	Health and safety and the environment
	Skills and questions
9	Gas welding, cutting and plasma arc
	Overview of gas welding
	Oxy-acetylene welding equipment
	Regulators
	Definitions of welding terms
	Welding rods and fluxes
	Flame control and types of flame
	Methods of welding
	Edge preparation and types of joint
	Welding technique: butt joint in mild steel
	Welding various metals
	Gas cutting
	Gases: characteristics and colour coding
	Safety measures
	Plasma arc cutting
	Skills and questions
10	Electric resistive welding
	Resistance welding in car body manufacture
	Resistance spot welding
	Resistance projection welding
	Resistance seam welding
	Resistance flash welding
	Resistance butt welding
	Resistance welding in body repair work
	Resistance spot welding of high-strength steels
	Weld quality
	ARO Spotrite Pulsa resistance welding system
	Single-sided spot welding
	Skills and questions
11	Manual metal arc welding (MMA)
	Principles of manual metal arc welding
	Electrical terms used in arc welding
	Metal arc welding equipment
	Electrodes used in welding: BS coding
	Arc welding positions
	Essential factors of arc welding
	Technique of welding
	Safety precautions for the welder
	Skills and questions
12	Gas shielded arc welding (MIG, MAG and TIG)
	Development of gas shielded arc welding
	Gases used for shielded arc processes
	TIG welding
	Application of TIG welding
	MIG/MAG welding
	MIG/MAG spot/plug welding
	Equipment used in MIG/MAG welding
	MIG/MAG welding techniques
	Applications of MIG/MAG welding in vehicle body construction
	Applications of MIG/MAG welding in body repair work
	MIG/MAG welding of low-carbon steel and HSLA steels
	Welding stress and distortion in the MIG/MAG process
	Weld testing and inspection
	Equipment maintenance and safety
	Skills and questions
13	Craft techniques and minor accident damage
	Panel beating: forming panels by hand
	Shaping metal by hand
	General guide to the fabrication of hand-made panels
	Edge stiffening of sheet metal
	Techniques of damage rectification
	Hammering techniques
	Filing
	Sanding or disc grinding
	Hot shrinking
	Cold shrinking
	Body soldering
	Chemically hardening fillers (plastic fillers)
	Body jack (hydraulic)
	Application of the body jack
	Repair of component motor body panels
	Aluminium panel repair
	Body electrical and electronic systems
	SAE J1930
	Skills and questions
14	Major accident damage repair
	Damage classification and assessment
	Pulling, alignment and repair systems used on major accident damage
	Alignment of the modern integral body
	Major repair techniques
	Skills and questions
15	Bodyshop planning
	Initial planning
	Planning the areas of the workshop
	Bodyshop heating
	Bodyshop lighting
	Essential equipment for the bodyshop
	Bodyshops and legal requirements
	Skills and questions
16	Reinforced composite materials
	Introduction
	Basic principles of reinforced composite materials
	Manufacture of reinforced composite materials
	Types of reinforcing material
	Resins used in reinforced composite materials
	Moulding techniques for reinforced composite laminates
	Repair of reinforced composite bodies
	Common faults in moulded laminates
	Safety precautions
	Skills and questions
17	Automotive finishing and re-finishing
	Glossary of terms used in spray painting
	Basic composition of paint
	Types of paint
	Materials used in refinishing
	Spray painting equipment
	Types of spray gun
	Basic parts of a standard spray gun
	Spray gun maintenance and cleaning
	Spray gun motion study
	Spraying defects
	Sanding and polishing machines
	Preparation of a motor vehicle for repainting
	Finishing and refinishing processes
	Burnishing, polishing and final detail work
	Rust-proofing
	Movement of vehicle in the paint shop
	Common spray painting defects
	Colour mixing and matching
	Vehicle cleaning – detailing
	Virtual-reality spraying
	Skills and questions
18	Case study
	General appearance
	Site selection
	Pre-planning
	Notable points
19	Mechanical, electrical and trim – MET
	Science
	Impact and momentum
	Batteries
	Repair pods
	Quick reference guide to vehicle systems
	Steering and suspension
	Skills and questions
Appendix 1: Health and safety risk assessment and COSHH data sheets
Glossary
Index