8
Auto Collision Repair and Refinishing
Alignment Bar........................................144
Door Removal and Alignment Tools ......144
Body Chisel...........................................145
Metal Files.............................................145
Bull’s-Eye Pick.......................................146
Panel Flanger........................................146
Hand Punch ..........................................146
Filler Tools .............................................146
Shaping and Sanding Tools...................147
Cable-Tensioning Devices.....................150
Panel Repair Power Tools
........................
151
Grinder ..................................................151
Air File...................................................152
Orbital Sander.......................................152
Spot Weld Cutters .................................153
Air Punch/Flanger .................................153
Cut-Off Tool ...........................................154
Air Chisel...............................................154
Air Saw..................................................154
Electric Shears......................................155
Door Skin Replacement Tool.................155
Draw Pin Welder ...................................156
Rod Welder ...........................................157
Weld-on Plate........................................157
Hydraulic Power Set..............................158
Nonstructural Repair Materials
..............
158
Body Fillers ...........................................158
Sandpaper.............................................159
Adhesives..............................................161
Chapter 8
Nonstructural Panel Repair.....................165
Introduction................................................. 166
Fundamentals of Damage Repair
..........
166
Nonstructural Panel Repair Steps
.........
166
Reading the Estimate............................167
Analyzing Damage................................167
Planning the Repair...............................168
Accessing Damage ...............................169
Roughing Out........................................171
Roughing Out Specific Types of Damage ..181
Arrowheads...........................................184
Finishing................................................187
Aluminum Panel Repair Operations....... 194
Chapter 9
Bolted Nonstructural Part
Replacement .................................................197
Introduction................................................. 198
Part Sources................................................ 198
OEM Parts.............................................198
Used Parts ............................................198
Aftermarket Parts ..................................199
Bolted Part Replacement Steps
.............
199
Read the Estimate.................................199
Analyze the Damage.............................199
Plan the Repair .....................................200
Remove the Damaged Parts.................200
Fit Up.....................................................200
Final Assembly......................................201
Replacing Specific Bolted Parts
............
201
Steel Bumpers.......................................202
Plastic Bumpers ....................................204
Header Panel ........................................206
Fenders.................................................207
Hood......................................................210
Doors.....................................................214
Deck Lid ................................................218
Rear Hatch............................................219
Sliding Door...........................................220
Pickup Bed............................................221
Chapter 10
Welded and Bonded Nonstructural Panel
Replacement .................................................225
Introduction................................................. 226
Welded and Bonded Nonstructural Panel
Replacement Steps............................. 226
Reading the Estimate............................226
Analyzing the Damage..........................226
Planning the Repair...............................227
Accessing the Damage .........................228
Rough Cutting .......................................228
Final Cutting..........................................231
Preparing Panels...................................231
Fit Up.....................................................233
Joining...................................................234
Finishing................................................236
Replacing Specific Nonstructural
Panels..................................................... 237
Quarter Panel Replacement..................237
Roof Replacement ................................240
Rear Body Panel Replacement.............244
Bed Side Replacement .........................244
Cab Corner Replacement .....................246
Van Side Replacement..........................247
Door Skin Replacement ........................247
Patch Panel Installation.........................251
Chapter 11
Plastic Repair................................................255
Introduction................................................. 256
Classifying Plastics................................... 257
Tools and Materials
...................................
257
Die Grinder............................................257
Plastic Welder .......................................257
Adhesives..............................................260