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