xvi Welding Fundamentals .................................... 117 Weld Types .......................................................... 118 Welding Position ................................................ 118 Joint Types........................................................... 119 Fit Up ................................................................... 119 Preparation for Welding ................................... 119 MIG Welding .....................................................120 Weld Terminology .............................................122 MIG Welding Variables .....................................123 MIG Welding Machine Setup ...........................125 Testing Welds ......................................................129 MIG Welding Aluminum ..................................129 MIG Brazing .......................................................132 Flux-Cored Arc Welding ..................................133 Resistance Welds ...............................................133 Squeeze-Type Resistance Spot Welding Machines ..........................................................134 Preparing for STRSW ........................................135 Squeeze-Type Resistance Spot Welding .........137 Panel Spotter .......................................................137 Using an Oxyacetylene Torch .........................138 Lighting an Oxyacetylene Torch ......................138 Heating Steel Parts ............................................139 Brazing ................................................................139 Cutting Steel Parts ............................................140 Using a Plasma Cutter ......................................140 Using an Oxyacetylene Cutting Torch ............141 SECTION 2 Nonstructural Repairs CHAPTER 8 Nonstructural Repair Tools, Equipment, and Materials 147 Introduction .......................................................148 Body Repair Hand Tools ..................................148 Body Hammers ..................................................148 Dollies ..................................................................150 Spoons .................................................................152 Picks .....................................................................152 Slide Hammer ....................................................152 Friction Jack ........................................................153 Alignment Bar ....................................................154 Cartridge Gun ....................................................154 Door Alignment Tool .........................................154 Body Chisel .........................................................154 Metal Files ...........................................................155 Bridge ..................................................................156 Hand Punch ........................................................156 Filler Tools ...........................................................156 Shaping and Sanding Tools ..............................157 Cable-Tensioning Devices ................................160 Panel Repair Power Tools ................................161 Grinder ................................................................161 Air File .................................................................161 Orbital Sander ....................................................162 Spot Weld Cutters ..............................................162 Belt Sander ..........................................................162 Cut-Off Tool/Grinder .......................................163 Air Chisel ............................................................163 Riveter .................................................................164 Door Skin Replacement Tool ............................165 Draw Pin Welder ................................................165 Rod Welder .........................................................166 Weld-On Plate ....................................................166 Hydraulic Power Set .........................................167 Nonstructural Repair Materials .....................168 Body Fillers .........................................................168 Sandpaper ...........................................................169 Aluminum Panel Repair Equipment ..............170 CHAPTER 9 Nonstructural Panel Repair 175 Introduction .......................................................176 Fundamentals of Damage Repair ..................176 Nonstructural Panel Repair Steps ..................176 Reading the Estimate.........................................176 Analyzing Damage ............................................176 Planning the Repair ...........................................178 Accessing Damage .............................................179 Roughing Out .....................................................181 Roughing Out Specifi c Types of Damage .......192 Arrowheads ........................................................194 Finishing ..............................................................197 Aluminum Panel Repair Operations ............204 CHAPTER 10 Bolted Nonstructural Part Replacement 209 Introduction .......................................................210 Part Sources ........................................................210 OEM Parts ...........................................................210 Used Parts ...........................................................210 Aftermarket Parts .............................................. 211