Auto Collision Repair and Refinishing, 2nd Edition Page xv (15 of 944)

xv
Copyright Goodheart-Willcox Co., Inc.
Component Shapes . . . . . . . . . . . 61
Collision Factors . . . 62
Force . . . . . . . . . . . . . . . . . 62
Inertia . . . . . . . . . . . . . . . . . 65
Target . . . . . . . . . . . . . . . . . 66
Impact Angle . . . . . . . . . . . . . . 66
Surface Area of Impact. . . . . . . . . . 66
Vehicle Height . . . . . . . . . . . . . 67
Damage . . . 67
Direct and Indirect Damage . . . . . . . 67
Bend-versus-Kink Rule . . . . . . . . . 68
Full-Frame Damage . . . . . . . . . . . 69
Unibody Damage . . . . . . . . . . . . 73
CHAPTER
5
General-Purpose Tools
and Equipment,
Service Information 81
Introduction . . . 82
Tool Storage . . . 82
General-Purpose Hand Tools . . . 83
Wrenches . . . . . . . . . . . . . . . 83
Pliers . . . . . . . . . . . . . . . . . 85
Screwdrivers . . . . . . . . . . . . . . 86
Pry Bars . . . . . . . . . . . . . . . . 86
Hammers . . . . . . . . . . . . . . . 86
Chisels and Punches. . . . . . . . . . . 87
Tap and Die Set . . . . . . . . . . . . . 88
Hacksaw. . . . . . . . . . . . . . . . 89
Snips . . . . . . . . . . . . . . . . . 89
Rivet gun . . . . . . . . . . . . . . . 89
Scrapers . . . . . . . . . . . . . . . . 90
Utility Knives . . . . . . . . . . . . . 90
Upholstery Removal Tools . . . . . . . . 91
Power Tools . . . 91
Impact Wrench . . . . . . . . . . . . . 91
Air Ratchet. . . . . . . . . . . . . . . 92
Drills and Drill Bits . . . . . . . . . . . 92
Shop Equipment . . . 92
Compressed Air System . . . . . . . . . 92
Floor Jack . . . . . . . . . . . . . . . 93
Jack Stands. . . . . . . . . . . . . . . 93
Lifts . . . . . . . . . . . . . . . . . . 94
Creepers and Shop Seats . . . . . . . . . 95
Service Cart . . . . . . . . . . . . . . 95
Welding Equipment . . . . . . . . . . . 96
Scan Tool . . . . . . . . . . . . . . . 96
Service Information . . . 96
CHAPTER
6
Fasteners 101
Introduction . . . 102
Galvanic Corrosion . . . 102
Threaded Fasteners . . . 102
Bolts . . . . . . . . . . . . . . . . . 102
Nuts . . . . . . . . . . . . . . . . . 104
Washers . . . . . . . . . . . . . . . . 105
Damage to bolts, nuts, and washers . . . . 105
Screws. . . . . . . . . . . . . . . . . 105
Threaded Fastener Service . . . . . . . . 106
Liquid Threadlock . . . . . . . . . . . 108
Anti-seize Lubricant . . . 108
Non-Threaded Fasteners . . . 109
Rings . . . . . . . . . . . . . . . . . 109
Rivets . . . . . . . . . . . . . . . . . 110
Adhesives . . . 111
Hybrid Bonding . . . 111
Plastic Fasteners . . . 111
CHAPTER
7
Welding and Cutting 115
Introduction . . . 116
Welding Safety . . . 116
Welding Fundamentals . . . 117
Weld Types. . . . . . . . . . . . . . . 118
Welding Position . . . . . . . . . . . . 118
Joint Types . . . . . . . . . . . . . . . 118
Fit Up . . . . . . . . . . . . . . . . . 119
Preparation for Welding . . . . . . . . . 119
MIG Welding . . . 119
Weld Terminology . . . . . . . . . . . 122
MIG Welding Variables . . . . . . . . . 122
MIG Welding Machine Setup . . . . . . . 125
Testing Welds. . . . . . . . . . . . . . 129
MIG Welding Aluminum. . . . . . . . . 130
MIG Brazing . . . . . . . . . . . . . . 132
Flux-Cored Arc Welding . . . 133
Tungsten Inert Gas Welding . . . 133

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Extracted Text (may have errors)

xv
Copyright Goodheart-Willcox Co., Inc.
Component Shapes . . . . . . . . . . . 61
Collision Factors . . . 62
Force . . . . . . . . . . . . . . . . . 62
Inertia . . . . . . . . . . . . . . . . . 65
Target . . . . . . . . . . . . . . . . . 66
Impact Angle . . . . . . . . . . . . . . 66
Surface Area of Impact. . . . . . . . . . 66
Vehicle Height . . . . . . . . . . . . . 67
Damage . . . 67
Direct and Indirect Damage . . . . . . . 67
Bend-versus-Kink Rule . . . . . . . . . 68
Full-Frame Damage . . . . . . . . . . . 69
Unibody Damage . . . . . . . . . . . . 73
CHAPTER
5
General-Purpose Tools
and Equipment,
Service Information 81
Introduction . . . 82
Tool Storage . . . 82
General-Purpose Hand Tools . . . 83
Wrenches . . . . . . . . . . . . . . . 83
Pliers . . . . . . . . . . . . . . . . . 85
Screwdrivers . . . . . . . . . . . . . . 86
Pry Bars . . . . . . . . . . . . . . . . 86
Hammers . . . . . . . . . . . . . . . 86
Chisels and Punches. . . . . . . . . . . 87
Tap and Die Set . . . . . . . . . . . . . 88
Hacksaw. . . . . . . . . . . . . . . . 89
Snips . . . . . . . . . . . . . . . . . 89
Rivet gun . . . . . . . . . . . . . . . 89
Scrapers . . . . . . . . . . . . . . . . 90
Utility Knives . . . . . . . . . . . . . 90
Upholstery Removal Tools . . . . . . . . 91
Power Tools . . . 91
Impact Wrench . . . . . . . . . . . . . 91
Air Ratchet. . . . . . . . . . . . . . . 92
Drills and Drill Bits . . . . . . . . . . . 92
Shop Equipment . . . 92
Compressed Air System . . . . . . . . . 92
Floor Jack . . . . . . . . . . . . . . . 93
Jack Stands. . . . . . . . . . . . . . . 93
Lifts . . . . . . . . . . . . . . . . . . 94
Creepers and Shop Seats . . . . . . . . . 95
Service Cart . . . . . . . . . . . . . . 95
Welding Equipment . . . . . . . . . . . 96
Scan Tool . . . . . . . . . . . . . . . 96
Service Information . . . 96
CHAPTER
6
Fasteners 101
Introduction . . . 102
Galvanic Corrosion . . . 102
Threaded Fasteners . . . 102
Bolts . . . . . . . . . . . . . . . . . 102
Nuts . . . . . . . . . . . . . . . . . 104
Washers . . . . . . . . . . . . . . . . 105
Damage to bolts, nuts, and washers . . . . 105
Screws. . . . . . . . . . . . . . . . . 105
Threaded Fastener Service . . . . . . . . 106
Liquid Threadlock . . . . . . . . . . . 108
Anti-seize Lubricant . . . 108
Non-Threaded Fasteners . . . 109
Rings . . . . . . . . . . . . . . . . . 109
Rivets . . . . . . . . . . . . . . . . . 110
Adhesives . . . 111
Hybrid Bonding . . . 111
Plastic Fasteners . . . 111
CHAPTER
7
Welding and Cutting 115
Introduction . . . 116
Welding Safety . . . 116
Welding Fundamentals . . . 117
Weld Types. . . . . . . . . . . . . . . 118
Welding Position . . . . . . . . . . . . 118
Joint Types . . . . . . . . . . . . . . . 118
Fit Up . . . . . . . . . . . . . . . . . 119
Preparation for Welding . . . . . . . . . 119
MIG Welding . . . 119
Weld Terminology . . . . . . . . . . . 122
MIG Welding Variables . . . . . . . . . 122
MIG Welding Machine Setup . . . . . . . 125
Testing Welds. . . . . . . . . . . . . . 129
MIG Welding Aluminum. . . . . . . . . 130
MIG Brazing . . . . . . . . . . . . . . 132
Flux-Cored Arc Welding . . . 133
Tungsten Inert Gas Welding . . . 133

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xiv
Copyright Goodheart-Willcox Co., Inc.
CONTENTS
Ear Protection . . . . . . . . . . . . . 26
Respiratory Protection . . . . . . . . . . 26
Skin Protection . . . . . . . . . . . . . 28
Safe Work Practices . . . 29
Welding and Cutting Safety . . . . . . . 29
Straightening Equipment Safety. . . . . . 31
Grinding and Cutting Safety . . . . . . . 32
Sanding Safety . . . . . . . . . . . . . 33
Painting Safety . . . . . . . . . . . . . 33
Mechanical Repair Safety . . . . . . . . 34
Hazardous Wastes . . . 36
Environmental Regulations . . . 36
Environmental Protection Agency . . . . . 36
Occupational Safety and Health
Administration . . . . . . . . . . . 38
CHAPTER
3
Vehicle Construction 41
Introduction . . . 42
Vehicle Classifi cations . . . 42
Vehicle Construction . . . . . . . . . . 42
Drive Train Orientation . . . . . . . . . 42
Body Styles . . . . . . . . . . . . . . 43
Material Types . . . 44
Steel. . . . . . . . . . . . . . . . . . 44
Aluminum . . . . . . . . . . . . . . . 47
Magnesium . . . . . . . . . . . . . . 48
Plastic . . . . . . . . . . . . . . . . . 48
Glass . . . . . . . . . . . . . . . . . 49
Vehicle Parts . . . 49
Outer Body Assemblies . . . . . . . . . 50
Inner Body Assemblies . . . . . . . . . 51
Sealants and Sound Deadeners . . . . . . 54
Vehicle Production . . . 54
Vehicle Safety Rating . . . 55
CHAPTER
4
Fundamentals of Collision
Damage 59
Introduction . . . 60
Vehicle Design Factors . . . 60
Metal Properties . . . . . . . . . . . . 60
SECTION
1
Introduction to Collision Repair
CHAPTER
1
Introduction to Collision
Repair 3
Introduction . . . 4
The Repair Process . . . 4
Insurance Claims . . . . . . . . . . . . . 4
Ordering Parts . . . . . . . . . . . . . . 5
Body Repairs . . . . . . . . . . . . . . . 7
Mechanical Repairs . . . . . . . . . . . . 8
Refi . . . . . . . . . . . . . . . 9 finishing.
Reassembly . . . . . . . . . . . . . . 10
Detailing. . . . . . . . . . . . . . . . 10
Body Shop Types . . . 10
Collision Repair Industry Jobs . . . 11
Body Shop Employees . . . . . . . . . . 11
Body Repair Support Positions . . . . . . 13
Educational Opportunities . . . 13
ASE . . . . . . . . . . . . . . . . . . 14
NATEF . . . . . . . . . . . . . . . . 14
I-CAR . . . . . . . . . . . . . . . . . 14
CHAPTER
2
Safety 7
Introduction . . . 18
Collision Repair Shop Hazards . . . 18
Fire Hazards . . . . . . . . . . . . . . 18
Explosion Hazards . . . . . . . . . . . 19
Chemical and Biological Hazards . . . . . 21
Electrical Hazards. . . . . . . . . . . . 22
Noise Hazards . . . . . . . . . . . . . 23
Injury Hazards . . . . . . . . . . . . . 23
Personal Protective Gear . . . 25
Eye Protection . . . . . . . . . . . . . 25

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Extracted Text (may have errors)

xiv
Copyright Goodheart-Willcox Co., Inc.
CONTENTS
Ear Protection . . . . . . . . . . . . . 26
Respiratory Protection . . . . . . . . . . 26
Skin Protection . . . . . . . . . . . . . 28
Safe Work Practices . . . 29
Welding and Cutting Safety . . . . . . . 29
Straightening Equipment Safety. . . . . . 31
Grinding and Cutting Safety . . . . . . . 32
Sanding Safety . . . . . . . . . . . . . 33
Painting Safety . . . . . . . . . . . . . 33
Mechanical Repair Safety . . . . . . . . 34
Hazardous Wastes . . . 36
Environmental Regulations . . . 36
Environmental Protection Agency . . . . . 36
Occupational Safety and Health
Administration . . . . . . . . . . . 38
CHAPTER
3
Vehicle Construction 41
Introduction . . . 42
Vehicle Classifi cations . . . 42
Vehicle Construction . . . . . . . . . . 42
Drive Train Orientation . . . . . . . . . 42
Body Styles . . . . . . . . . . . . . . 43
Material Types . . . 44
Steel. . . . . . . . . . . . . . . . . . 44
Aluminum . . . . . . . . . . . . . . . 47
Magnesium . . . . . . . . . . . . . . 48
Plastic . . . . . . . . . . . . . . . . . 48
Glass . . . . . . . . . . . . . . . . . 49
Vehicle Parts . . . 49
Outer Body Assemblies . . . . . . . . . 50
Inner Body Assemblies . . . . . . . . . 51
Sealants and Sound Deadeners . . . . . . 54
Vehicle Production . . . 54
Vehicle Safety Rating . . . 55
CHAPTER
4
Fundamentals of Collision
Damage 59
Introduction . . . 60
Vehicle Design Factors . . . 60
Metal Properties . . . . . . . . . . . . 60
SECTION
1
Introduction to Collision Repair
CHAPTER
1
Introduction to Collision
Repair 3
Introduction . . . 4
The Repair Process . . . 4
Insurance Claims . . . . . . . . . . . . . 4
Ordering Parts . . . . . . . . . . . . . . 5
Body Repairs . . . . . . . . . . . . . . . 7
Mechanical Repairs . . . . . . . . . . . . 8
Refi . . . . . . . . . . . . . . . 9 finishing.
Reassembly . . . . . . . . . . . . . . 10
Detailing. . . . . . . . . . . . . . . . 10
Body Shop Types . . . 10
Collision Repair Industry Jobs . . . 11
Body Shop Employees . . . . . . . . . . 11
Body Repair Support Positions . . . . . . 13
Educational Opportunities . . . 13
ASE . . . . . . . . . . . . . . . . . . 14
NATEF . . . . . . . . . . . . . . . . 14
I-CAR . . . . . . . . . . . . . . . . . 14
CHAPTER
2
Safety 7
Introduction . . . 18
Collision Repair Shop Hazards . . . 18
Fire Hazards . . . . . . . . . . . . . . 18
Explosion Hazards . . . . . . . . . . . 19
Chemical and Biological Hazards . . . . . 21
Electrical Hazards. . . . . . . . . . . . 22
Noise Hazards . . . . . . . . . . . . . 23
Injury Hazards . . . . . . . . . . . . . 23
Personal Protective Gear . . . 25
Eye Protection . . . . . . . . . . . . . 25

xvi
Copyright Goodheart-Willcox Co., Inc.
Resistance Welding . . . 134
Squeeze-Type Resistance Spot Welding
Machines. . . . . . . . . . . . . . . 134
Panel Spotter . . . . . . . . . . . . . . 135
Using an Oxyacetylene Torch . . . 136
Lighting an Oxyacetylene Torch. . . . . . 136
Heating Steel Parts . . . 137
Brazing . . . 138
Cutting Steel Parts . . . 138
Using a Plasma Cutter . . . . . . . . . . 138
Using an Oxyacetylene Cutting Torch . . . 139
SECTION
2
Nonstructural Repairs
CHAPTER
8
Nonstructural Repair
Tools, Equipment,
and Materials 145
Introduction . . . 146
Body Repair Hand Tools . . . 146
Body Hammers . . . . . . . . . . . . . 146
Dollies. . . . . . . . . . . . . . . . . 149
Spoons . . . . . . . . . . . . . . . . 150
Picks . . . . . . . . . . . . . . . . . 150
Slide Hammer . . . . . . . . . . . . . 150
Friction Jack . . . . . . . . . . . . . . 151
Alignment Bar . . . . . . . . . . . . . 152
Door Removal and Alignment Tools . . . . 152
Body Chisel . . . . . . . . . . . . . . 152
Metal Files . . . . . . . . . . . . . . . 153
Bull’s-Eye Pick . . . . . . . . . . . . . 154
Panel Flanger. . . . . . . . . . . . . . 154
Hand Punch . . . . . . . . . . . . . . 154
Filler Tools . . . . . . . . . . . . . . . 154
Shaping and Sanding Tools. . . . . . . . 155
Cable-Tensioning Devices . . . . . . . . 158
Panel Repair Power Tools . . . 159
Grinder . . . . . . . . . . . . . . . . 159
Air File . . . . . . . . . . . . . . . . 160
Orbital Sander . . . . . . . . . . . . . 160
Spot Weld Cutters. . . . . . . . . . . . 160
Air Punch/Flanger . . . . . . . . . . . 161
Cut-Off Tool . . . . . . . . . . . . . . 161
Air Chisel . . . . . . . . . . . . . . . 162
Air Saw . . . . . . . . . . . . . . . . 162
Electric Shears . . . . . . . . . . . . . 162
Door Skin Replacement Tool . . . . . . . 162
Draw Pin Welder . . . . . . . . . . . . 163
Rod Welder . . . . . . . . . . . . . . 164
Weld-On Plate . . . . . . . . . . . . . 165
Hydraulic Power Set . . . . . . . . . . 165
Nonstructural Repair Materials . . . 166
Body Fillers . . . . . . . . . . . . . . 166
Sandpaper . . . . . . . . . . . . . . . 167
Aluminum Panel Repair Equipment . . . . 168
CHAPTER
9
Nonstructural
Panel Repair 173
Introduction . . . 174
Fundamentals of Damage Repair . . . 174
Nonstructural Panel Repair Steps . . . 174
Reading the Estimate . . . . . . . . . . 174
Analyzing Damage . . . . . . . . . . . 175
Planning the Repair . . . . . . . . . . . 176
Accessing Damage . . . . . . . . . . . 177
Roughing Out . . . . . . . . . . . . . 179
Roughing out Specifi Types fic
of Damage . . . . . . . . . . . . . . 190
Arrowheads . . . . . . . . . . . . . . 192
Finishing. . . . . . . . . . . . . . . . 195
Aluminum Panel Repair Operations . . . 202
CHAPTER
10
Bolted Nonstructural
Part Replacement 207
Introduction . . . 208
Part Sources . . . 208
OEM Parts . . . . . . . . . . . . . . . 208
Used Parts . . . . . . . . . . . . . . . 208
Aftermarket Parts . . . . . . . . . . . . 209

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Page 2Section 1 Introduction to Collision Repair click to expand contents

Page 144Section 2 Nonstructural Repairs click to expand contents

Page 316Section 3 Structural Repairs click to expand contents

Page 456Section 4 Mechanical and Electrical Repairs click to expand contents

Page 594Section 5 Refinishing click to expand contents

Page 816Section 6 Estimating and Certification click to expand contents

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