7
Chapter 4
Fundamentals of Collision Damage
......
69
Introduction....................................................70
Vehicle Design Factors................................70
Metal Properties......................................70
Component Shapes ................................71
Collision Factors...........................................72
Force.......................................................72
Inertia......................................................75
Target ......................................................76
Impact Angle ...........................................76
Surface Area of Impact ...........................76
Vehicle Height .........................................77
Damage............................................................77
Direct and Indirect Damage ....................78
Bend-versus-Kink Rule ...........................79
Full-Frame Damage ................................79
Unibody Damage ....................................83
Chapter 5
Welding and Cutting
....................................
89
Introduction....................................................90
Welding Safety...............................................90
Welding Fundamentals................................92
Weld Types..............................................92
Welding Position......................................92
Joint Types ..............................................93
Fit Up.......................................................93
Preparation for Welding...........................93
MIG Welding ...................................................93
Weld Terminology....................................96
MIG Welding Variables............................96
MIG Welding Machine Setup...................98
Testing Welds........................................102
MIG Welding Aluminum.........................104
Flux-Cored Arc Welding
...........................
105
Tungsten Inert Gas Welding
....................
106
Resistance Welding................................... 107
Squeeze-Type Resistance Spot
Welding Machines.................................107
Panel Spotter ........................................109
Using an Oxyacetylene Torch
.................
109
Lighting an Oxyacetylene Torch ............110
Heating Steel Parts.................................... 110
Brazing
.........................................................
111
Cutting Steel Parts..................................... 111
Using a Plasma Cutter ..........................111
Using an Oxyacetylene Cutting Torch ...112
Chapter 6
General Purpose Tools and Equipment,
Service Information....................................117
Introduction................................................. 118
Tool Storage................................................ 118
General-Purpose Hand Tools
..................
119
Wrenches..............................................119
Pliers .....................................................121
Screwdrivers .........................................122
Pry Bars ................................................122
Hammers...............................................123
Chisels and Punches ............................123
Tap and Die Set.....................................124
Hacksaw................................................125
Snips.....................................................125
Rivet gun...............................................125
Scrapers................................................126
Utility Knives..........................................126
Upholstery Removal Tools.....................126
Power Tools
.................................................
127
Impact Wrench ......................................127
Air Ratchet ............................................127
Drills and Drill Bits.................................127
Shop Equipment
........................................
128
Compressed Air System .......................128
Floor Jack..............................................128
Jack Stands...........................................129
Lifts........................................................129
Creepers and Shop Seats.....................131
Service Cart ..........................................131
Welding Equipment...............................131
Service Information................................... 132
Section 2
Chapter 7
Nonstructural Repair Tools,
Equipment, and Materials ........................137
Introduction................................................. 138
Body Repair Hand Tools........................... 138
Body Hammers .....................................138
Dollies ...................................................141
Spoons..................................................142
Picks......................................................142
Slide Hammer .......................................143
Friction Jack ..........................................143
Nonstructural Repairs