Auto Collision Repair and Refinishing 3e, Online Textbook Page xiv (14 of 960)

xiv Contents 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 Pre-Scanning and Blueprinting ............................6 Body Repairs ..........................................................7 Mechanical Repairs................................................8 Refi nishing ..............................................................9 Reassembly .............................................................9 Recalibration and Post-Scan ...............................10 Detailing ................................................................10 Body Shop Types ................................................. 11 Collision Repair Industry Jobs .........................12 Body Shop Employees ........................................12 Body Repair Support Positions ..........................13 Educational Opportunities ................................14 ASE.........................................................................14 ASE Education Foundation ................................14 I-CAR .....................................................................15 CHAPTER 2 Safety 17 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 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 ..................................................37 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 Corrosion Protection ...........................................54 Sealants and Sound Deadener ...........................54 Vehicle Production ..............................................54 Vehicle Safety Rating .........................................55

Previous Page Next Page

Extracted Text (may have errors)

xiv Contents 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 Pre-Scanning and Blueprinting ............................6 Body Repairs ..........................................................7 Mechanical Repairs................................................8 Refi nishing ..............................................................9 Reassembly .............................................................9 Recalibration and Post-Scan ...............................10 Detailing ................................................................10 Body Shop Types ................................................. 11 Collision Repair Industry Jobs .........................12 Body Shop Employees ........................................12 Body Repair Support Positions ..........................13 Educational Opportunities ................................14 ASE.........................................................................14 ASE Education Foundation ................................14 I-CAR .....................................................................15 CHAPTER 2 Safety 17 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 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 ..................................................37 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 Corrosion Protection ...........................................54 Sealants and Sound Deadener ...........................54 Vehicle Production ..............................................54 Vehicle Safety Rating .........................................55

Help

xv CHAPTER 4 Fundamentals of Collision Damage 59 Introduction .........................................................60 Vehicle Design Factors .......................................60 Metal Properties ...................................................60 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 Power Ratchet ......................................................92 Drills, Drivers, and Drill Bits .............................92 Shop Equipment ..................................................92 Compressed Air System ......................................92 Floor Jack...............................................................93 Jack Stands ............................................................94 Lifts ........................................................................94 Creepers and Shop Seats .....................................95 Battery Charger ....................................................95 Welding Equipment .............................................96 Scan Tool ..............................................................96 Service Information ............................................97 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 ..........................................109 Non-Threaded Fasteners ..................................109 Rings ....................................................................109 Rivets ...................................................................109 Adhesives ............................................................ 111 Hybrid Bonding ................................................ 111 Plastic Fasteners ................................................ 112 CHAPTER 7 Welding and Cutting 115 Introduction ....................................................... 116 Welding Safety .................................................. 116

Previous Page Next Page

xiii Brief Contents Section 1 Introduction to Collision Repair 1 Introduction to Collision Repair ............ 3 2 Safety ......................................................... 17 3 Vehicle Construction ............................... 41 4 Fundamentals of Collision Damage ..... 59 5 General-Purpose Tools and Equipment, Service Information ........... 81 6 Fasteners ..................................................101 7 Welding and Cutting ..............................115 Section 2 Nonstructural Repairs 8 Nonstructural Repair Tools, Equipment, and Materials .....................147 9 Nonstructural Panel Repair ...................175 10 Bolted Nonstructural Part Replacement .............................................209 11 Welded and Bonded Nonstructural Panel Replacement ..................................239 12 Plastic Repair ...........................................271 13 Glass ..........................................................297 Section 3 Structural Repairs 14 Unibody/Frame Straightening Equipment ................................................319 15 Measurements..........................................343 16 Unibody Straightening ...........................369 17 Full-Frame Repair ...................................397 18 Structural Component Replacement ....427 Section 4 Mechanical and Electrical Repairs 19 Steering and Suspension .........................457 20 Electrical System ......................................495 21 Brakes .........................................................519 22 Cooling, Heating, and Air Conditioning Systems .............................535 23 Power Train ...............................................555 24 Restraint Systems .....................................577 Section 5 Refi nishing 25 Refi nishing Tools and Equipment .........599 26 Refi nish Materials ....................................631 27 Paint Mixing and Reducing ....................659 28 Spray Technique .......................................677 29 Surface Preparation ..................................701 30 Color Matching .........................................733 31 Paint Application .....................................753 32 Specialty Painting .....................................781 33 Detailing ....................................................797 Section 6 Estimating and Certifi cation 34 Estimating .................................................821 35 ASE Certifi cation ......................................855 36 Employment Strategies and Employability Skills .................................865

Previous Page Next Page

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

Page 146Section 2 Nonstructural Repairs click to expand contents

Page 318Section 3 Structural Repairs click to expand contents

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

Page 598Section 5 Refinishing click to expand contents

Page 820Section 5 Estimating and Certification click to expand contents

Extracted Text (may have errors)

Help

loading