The Repair of Vehicle Bodies

Description

Cover Title Copyright Dedication Contents Preface 1 Car body construction Starting out Vehicle safety testing Elements of vehicle construction Vehicle information code plate Brief history of the motor vehicle Skills and questions 2 Health and safety and the environment Personal health and safety procedures Fire precautions Fire risks in the workshop Safety signs in the workshop General safety precautions in the workshop Electrical hazards COSHH RIDDOR Maintain the health, safety and security of the work environment Where identified hazards cannot be removed, appropriate action is taken immediately to minimize risk to own and others’ health and safety Skills and questions 3 Hand and power tools Hand tools used in body repair work Hammers Hand dollies Body spoons Body files Hand snips Specialist panel beating tools Clamps Punches Edge setters or jogglers Sheet metal bench stakes Hand grooving tools Rivet sets Cutting tools Bending and swaging tools General-purpose assembly and dismantling tools Skills and questions 4 Materials used in vehicle bodies Skills Aluminium Rubber Sealers Sound-deadening, thermal insulating and undersealing materials Interior furnishings Plastics Amorphous and crystalline plastics Abbreviations for automotive plastics Types of plastics Repair procedures Painting plastics Safety glass Skills and questions 5 Metal forming processes Properties of metals Heat treatment of steel and aluminium Machines for sheet metal fabrication Cutting machines Bending theory Bending machines Rolling machines Forming and drawing Sheet metal cutting for press work Skills and questions 6 Marking out and measuring Marking out Manufacture of templates Basic marking-out and measuring instruments Precision marking-out and measuring instruments Micrometer Skills and questions 7 Methods of joining Solid rivets Types of riveted joint Blind rivets Repetition rivets Rivet selection Structural fasteners Screws and bolts Fastening devices Adhesives Selection of adhesives Achieving good results with adhesives Adhesives and the automotive industry Skills and questions 8 Soft and hard soldering methods Comparison of fusion and non-fusion jointing processes Soft and hard solders Soft soldering Hard soldering Body leading/body soldering Health and safety and the environment Skills and questions 9 Gas welding, cutting and plasma arc Overview of gas welding Oxy-acetylene welding equipment Regulators Definitions of welding terms Welding rods and fluxes Flame control and types of flame Methods of welding Edge preparation and types of joint Welding technique: butt joint in mild steel Welding various metals Gas cutting Gases: characteristics and colour coding Safety measures Plasma arc cutting Skills and questions 10 Electric resistive welding Resistance welding in car body manufacture Resistance spot welding Resistance projection welding Resistance seam welding Resistance flash welding Resistance butt welding Resistance welding in body repair work Resistance spot welding of high-strength steels Weld quality ARO Spotrite Pulsa resistance welding system Single-sided spot welding Skills and questions 11 Manual metal arc welding (MMA) Principles of manual metal arc welding Electrical terms used in arc welding Metal arc welding equipment Electrodes used in welding: BS coding Arc welding positions Essential factors of arc welding Technique of welding Safety precautions for the welder Skills and questions 12 Gas shielded arc welding (MIG, MAG and TIG) Development of gas shielded arc welding Gases used for shielded arc processes TIG welding Application of TIG welding MIG/MAG welding MIG/MAG spot/plug welding Equipment used in MIG/MAG welding MIG/MAG welding techniques Applications of MIG/MAG welding in vehicle body construction Applications of MIG/MAG welding in body repair work MIG/MAG welding of low-carbon steel and HSLA steels Welding stress and distortion in the MIG/MAG process Weld testing and inspection Equipment maintenance and safety Skills and questions 13 Craft techniques and minor accident damage Panel beating: forming panels by hand Shaping metal by hand General guide to the fabrication of hand-made panels Edge stiffening of sheet metal Techniques of damage rectification Hammering techniques Filing Sanding or disc grinding Hot shrinking Cold shrinking Body soldering Chemically hardening fillers (plastic fillers) Body jack (hydraulic) Application of the body jack Repair of component motor body panels Aluminium panel repair Body electrical and electronic systems SAE J1930 Skills and questions 14 Major accident damage repair Damage classification and assessment Pulling, alignment and repair systems used on major accident damage Alignment of the modern integral body Major repair techniques Skills and questions 15 Bodyshop planning Initial planning Planning the areas of the workshop Bodyshop heating Bodyshop lighting Essential equipment for the bodyshop Bodyshops and legal requirements Skills and questions 16 Reinforced composite materials Introduction Basic principles of reinforced composite materials Manufacture of reinforced composite materials Types of reinforcing material Resins used in reinforced composite materials Moulding techniques for reinforced composite laminates Repair of reinforced composite bodies Common faults in moulded laminates Safety precautions Skills and questions 17 Automotive finishing and re-finishing Glossary of terms used in spray painting Basic composition of paint Types of paint Materials used in refinishing Spray painting equipment Types of spray gun Basic parts of a standard spray gun Spray gun maintenance and cleaning Spray gun motion study Spraying defects Sanding and polishing machines Preparation of a motor vehicle for repainting Finishing and refinishing processes Burnishing, polishing and final detail work Rust-proofing Movement of vehicle in the paint shop Common spray painting defects Colour mixing and matching Vehicle cleaning – detailing Virtual-reality spraying Skills and questions 18 Case study General appearance Site selection Pre-planning Notable points 19 Mechanical, electrical and trim – MET Science Impact and momentum Batteries Repair pods Quick reference guide to vehicle systems Steering and suspension Skills and questions Appendix 1: Health and safety risk assessment and COSHH data sheets Glossary Index