Procedure for identifying a
Particular colour
1 Note the make and year of manufacture of the
vehicle.
2 Find the colour identification plate on the vehicle
(the positioning of this varies from one
vehicle manufacturer to another) and note the
colour coding.
3 Select the appropriate microfiche, place it in
the viewer and find the mixing formula.
4 Double check that the correct colour has been
found by finding the coloured sample in the
books provided by the paint manufacturer, and
placing this against a cleaned-up part of the car.
5 If this does not match perfectly, check the book
on colour variants and consult the manufacturer’s
hints on tinting.
Hints on colour mixing
And matching
Never try to match a colour by dabbing a sample of
the colour on to the vehicle and making adjustments.
Colours alter during the drying process.
Always spray a sample card with the appropriate
number of coats and allow it to dry before comparing
it with the colour to be matched.
On a volumetric system, never use a dented tin or
one with a concaved or convexed bottom to mix the
colour in. On a gravimetric system, always remember
to place the tin on the scales before zeroing them.
When comparing the painted sample against the
vehicle, daylight, perferably from a northern source,
is best. Bright sunlight or artificial lighting can
sometimes exaggerate or diminish a colour effect.
Questions
1 State three of the advantages to be gained from
the method used by vehicle manufacturers for
applying the priming coat.
2 State two advantages to be gained by using a
guide coat when sanding down a surface.
3 Explain two of the functions of a spray gun air cap.
4 Explain how a suctionfed (or syphonfed) spray
gun operates.
5 Determine the difference between thermoplastic
and thermosetting paint coatings.
6 What is the basic difference between those
paints classed as lacquers and those classed as
enamels?
7 What is the function of a ground coat?
8 Under what circumstances would a bleeder-type
spray gun be selected in preference to a
non-bleeder?
9 Why are bleeder-type colours a problem to the
painter?
10 Explain the working principle of a single-acting,
two-stage, piston-type compressor.
11 What is meant by the pot life of a two-pack paint?
12 Give two reasons why cellulose-based paints
were replaced by stoving synthetics for mass
production finishing on new cars.
13 What type of vehicle finish is liable to become
viscid when dry sanded with a sanding tool?
626Repair of Vehicle Bodies
14 Reduced tinters have one-tenth of the tinting
strength of a full-strength tinter.Why are they
necessary for inclusion in colour mixing
schemes?
15 What is the best type of priming paint to use on
an aluminium surface?
16 What would be the most likely result of using
two-pack polyester stopper as an intercoat
stopper in a lacquer-type paint system?
17 State the main disadvantage of a combined spray
booth and low-bake oven unit.
18 What is the main health hazard associated with
the spraying of two-pack paints?
19 Which method of heat transfer is used in
(a) infrared and (b) low-bake heating units?
20 State two reasons why door handles should not
be ‘bandaged’ when masking up.
21 In which way do thermoplastic vehicle finishes
present problems to the vehicle refinisher when
carrying out spot repairs?
22 What is an HVLP spray gun?
23 It is estimated that 80–90 per cent of corrosion
on motor vehicles is classified as inside-out
corrosion. What steps do vehicle manufacturers
take to minimize this problem?
24 The spray pattern of a spray gun is top heavy.
Describe a simple process to determine whether
it is the air cap or fluid tip which is at fault.
25 State what is meant by ‘VOCs’.
26 How do HVLP spray guns and VOCs relate to
one another?
27 What is the main disadvantage of a combi-unit
(spray booth and low-bake oven)?
28 What is the difference between baking and
force-drying a paint film?
29 Describe a simple test to determine whether or
not an existing paint finish is of the
non-convertible type.
30 State three problems which can arise if cellulose
stopper is applied too heavily.
Adhesion 257
Adhesives 223–4
achieving good results 228
body repair 233
classification chart 143
curing times 227
hot metals 228, 231–2
joint function 227
joint types
butt 226
co-axial 226
plain lap 226
non-structural 228
selection by computer 227–8
service conditions 227
surface preparation 229–31
toughened structural 232–3
types
anaerobics 224
cyanoacrylates 224
epoxies 224–5
hot melts 225
phenolics 225
plastisols 225
polyurethanes 225–6
solvent-borne rubber 226
tapes 226
toughened 226
Advanced high-strength steel (AHSS) 131–2
Aerodynamics 23
drag 23–4
Air power chisel 110
Alignment
bonnet 446, 448–9
boot lid 449
digital measuring tool 441
door 444–6
misalignment and vehicle control 438
underbody
drop-line method 439
gunsight gauge method 439–41
jig fixtures 442
underframe 438
upper structure 443–4
Alloy steels 263–4
chromium 130
cobalt 130
high-alloy 130
low-alloy 130
manganese 130
molybdenum 130
nickel 130
niobium 130
silicon 130
titanium 130
tungsten 130
vanadium 130
Aluminium 133–4, 264, 307, 366
manufacturing process 134–5, 141
production 134
repairing 390–8
types of sheet 134
Aluminium alloys 134
availability, physical properties, applications 140
chemical composition limits, mechanical
properties 137–9
commonly used elements 134–5
general characteristics 136
heat-treatable 134
heat treatment 166–7
non-heat-treatable 134
used in bodywork 135, 141
Aluminium brazing 243
wetting and fluxing 243, 245
Amorphous plastics 150
Anticorrosion classification chart 143
ARO Spotrite Pulsa system 287–9
setting up equipment 289–90
welding procedure 290
Assembly/dismantling tools 105–6
screwdrivers 108–9
socket sets 107–8
spanners/wrenches 106–7
toolchests 109
Automotive finishing
basic composition of paint 577
burnishing, polishing, final detail work 614–16
colour mixing and matching 624–5
common spray painting defects 622–4
history 574–6
hot vs cold spraying 620–1
materials used in refinishing 579–82
movement of vehicle in paint shop 621
preparation of motor vehicle 600–2
refinishing processes 602–14
rust-proofing 616–20
Index
628Index
Automotive finishing (Continued)
sanding and polishing machines 598–600
spray guns 584–95
spray painting equipment 582–4
spray painting terms 576–7
spraying defects 595–8
types of paint 577–9
Bending machines
angle bender/clamp folder 172
box/pan (universal) 173
edge folder 172
open-end folder 172–3
safety measures 173
Bending theory 171
behaviour of metal 171
calculation 172
Bending tools 104–5
Blackhawk PB30 system 428
Blended plastics 150
Blind rivets
POP 200
blind 204
ELF 203
grooved 202
LSR 201
MGR 201–2
peel 203
special 203
standard open 200–1
well nut 204
repetition 204
Briv system 206
Chobert Grovit system 205–6
Chobert system 204–5
selection
diameter 207
edge distance 208
hole size 207
mandrel type 208
pitch of rivets 207–8
rivet length 207
rivet material 208
tools 206–7
Body engineering 27
Body files
abrasive 91
body file blades 91
flat 91
flexible panel 90–1
Body jack (hydraulic)
application
example 378–9
pulling 376
pushing 375–6
spreading 376–7
stretching/tensioning 377–8
basic equipment 373–5
care/maintenance 379
bleeding 379–80
hose 380
threads on ram/attachments 380
development/principles 372–3
Body pressings 43–52
Body shell 51
panels 129
Body side frame 46–7
Body soldering 367
composition/requirements 367
process 367–8
Body spoons 89
drip moulding 90
general-purpose 89–90
heavy-duty pry 90
high-crowned 90
long-reach 90
pry/surfacing 90
spring hammering 90
surface 89
thin 90
Body style terminology 10–11
Bodyshop planning
administration offices 503, 505, 507
choosing a site 501–2
essential equipment 512
dust/fume extraction 513–15
general workshop 513
hand tools/power tools 513
miscellaneous/expendable items 513
specialist stripping, repairing, painting 512–13
final inspection area 505
fire fighting equipment 504, 508–9
first aid equipment 508
general body repair area 505, 507
heating 509
conventional fixed systems 510
electric 509
gas 510
portable 510
radiant 509
legal requirements 502, 515–28
light sources
fluorescent tubes 512
high pressure sodium 512
mercury lamps 512
tungsten bulbs 512
lighting 510
paint mixing room 511
preparation area 510–11
Index 629
spray booth/painting area 511–12
stripping/straightening areas 510
parts department for trade/retail 504, 507
preparation area 505, 508
preplanning 501
principles/dimensions
entrances 503
roof supports 503
workshop floor space 503
quality management (BS EN ISO 9001–2000) 528–30
reception area 503, 505
refinishing area 505, 508
refit area 505
specialist repair area/jig area 505, 507
staff facilities 504
stripping area 505
valeting/wax injection area 505, 508
vehicle damage assessment area 505, 507
workshop layout 502–3
Bolts 215
countersunk head 215
hexagon head 215
Bonded windscreen electric cutter 119
Bonnet 50–1
alignment 446, 448–9
repair work 386–7
Boot floor 46
Boot lid 50
Boron steel 132–4
Brake presses 178–9
Brazing 240
advantages 242
aluminium 243, 245
bronze 245–7
process 240, 242
Breathing protection, see Respiratory
protection
Bronze welding 245–6
procedure 246–7
welding rods and fluxes 246
Car Bench 419
autocontrol measuring system 421
centre-post bench 421
mini bracket/support system 421
mobile bench 419
mobile lift 419–20
scissor-action lift 420
standard four-post lift 420–1
unified support system 421
Car-O-Liner system
BenchRack 431
Mark 5 collision repair 428–31
measuring 431
Carbon steel 124–5, 263
heat treatment 164–6
Cast iron 264
Celette UK system 412
benches 413–14
Bodymaster 2000 drive-on system 417–18
ECO 2000 mobile lifting trolley 418
jig lifts 414
Metro 2000 measurement 416–17
Metro 90 measurement 418
MZ system 414–16
Celluloid 2
Chemically hardening fillers (plastic fillers)
368, 370–2
Chief E-Z Liner II system 432–3
Chrome-vanadium steel 130
Clamps
C clamp 95
sheet metal 95
welding 95
Clips
cable 220
non-metal 221
push-on 221
Cold chisels 103
Cold shrinking 366–7
Complex phase (CP) steel 131
Construction method 32
body shape variations 37
composite (conventional separate
chassis) 32, 34
galvanized with composite skin panels 35, 37
glass fibre composite 35
integral (mono/unity) 34–5
semi-integral 35
Consultants 530
Control of Substances Hazardous to Health
(COSHH) Regulations (1988) 75,
76–7, 517–21
Copper-phosphorus brazing alloys 241
Corrosive fluxes 237
hydrochloric acid 237
phosphoric acid 237
zinc chloride (killed spirits) 237
Cutting machines
guillotine 170–1
hand lever shears 169–70
universal shearing 170
Cutting tools
cold chisels 103
drill attachment 104
hacksaws 103–4
hand snips 102–3
mini sheet metal 104
monodex cutters 103
630Index
Damage rectification 356–8
Dataliner repair system 424
drive-on rack 426
laser check 426–7
measuring 424–5
straightening equipment 425–6
Design
computer-aided 15
concept to realization 14–32
ergonomics 16
evolution 11, 14
stages 15
styling 15–16
Dismantling tools, see Assembly/dismantling
tools
Distortion control 260–3
Doors 49–50
Dozer equipment 407–8
Drawing operations 180–2
box 180, 182
cupping 180
panel 182
Drill cutting attachment 104
Dual phase (DP) steel 131
Duramix 477–8
Dust extraction 119–20
Edge joint 256
Edge preparation 260
control of distortion 260–3
Edge setter 105
Edge treatment 353–4
flanging 354–5
folding 354
swaging 355–6
wiring 356
Electrical and electronic systems 398
airbags 401
alternator 400
battery 400
central locking 400
control unit 401–2
electric seat 400–1
electric sunroof 400
electric windows 400
electronic control unit (ECU) 400
lights 401
release sensors 402
rotary coupling 402
safety check
air conditioning 403
checklist 403
crash sensors 403
do 402
do not 403
fuses 403
security/alarm systems 403
sensors 403
supplementary restraint system (SRS) 401
terms 398–9
warning light 402
wiring harness 402
Electrical terms
amp 398
amperes 295
analogue and digital meters 398
capacitor 398
circuit 295
diode 399
direct and alternating current 295
earth return 399
fuse 399
open circuit 399
open-circuit voltage and arc voltage 295
parallel 399
resistance 398
resistor 398
series 399
short circuit 399
transistor 399
volt 398
voltage 295
voltage drop 295
watt 398
Engine performance/testing 23
Environment Protection Act (1990) 522–3
EuroNCAP 27–30
Fabrication of hand-made panels 350–3
Fabrication tools
hammers 98–9
mallets 99–100
Fasteners
Christmas-tree buttons 222
D type edge fasteners 223
push-in panel (W-buttons) 222
quick-release 223
snapsacs 223
trim panel 222–3
Fastening devices
cable clip 220
captive nut, J type 219–20
captive nut, U type 218–19
non-metal clips 221
nut grip 220
plastic captive nuts/trim panel fasteners 221–2
push-on clips 221
spire speed nut 218
Index 631
Filler rods 257
Fillet welds 256
Filling 362–3
Fire
gas cylinders 269
plasma arc cutting 275
reinforced composite materials hazards 573
Fire precautions
definition of fire 66–7
general 68
methods of extinction 67
removal of fuel 67
removal of heat 67
removal/limitation of oxygen 67
portable extinguishers
carbon dioxide 70
choosing/siting 70
colour codes 68
dry powder 70
foam 68, 70
spray foam 70
vaporizing liquid 70
water 68
risk in workshop 67–8
body filler 68
class A: wood, paper, cloth 67
class B: flammable liquids 67
class C: gases 67
electrical hazards 67–8
Flame control
adjustment/gas pressure 258
power of flame 258
temperature 257
carbonizing, carburizing, reducing 257–8
natural flame 258
oxidizing flame 258
Flexible polyurethane 142
Floor (main) 46
Fluid dynamics
Ahmed model 32
calculations 31–2
definition 30–1
grid system 32
Reynolds Number 31
Fluxes 237–8, 243, 246, 257, 271
Foam rubber 142
Forming 180
Front-end assembly (including cowl/dash panel) 43, 46
Front side member 46
Fusion
skin 235
surface 235–6
total 235
Fusion face 256
Fusion zone 256
Gas cutting 264
flame 264
hand cutting procedure 266
machine 266
nozzles 265–6
torch 264–5
Gas metal arc welding (GMAW) 309
Gas shielded arc testing, equipment maintenance/safety
340–1
Gas shielded arc welding
development 309
gases used 310–11
argon 311
argon mixtures 312
carbon dioxide 311–12
choice 312
helium 311
helium mixtures 312
metal active gas (MAG) 309, 319–38
metal inert gas (MIG) 309, 319–38
tungsten inert gas (TIG) 309,
312–19
see also Manual metal arc welding (MMAW);
Resistance welding; Single-sided spot
welding;Welding
Gas tungsten arc welding (GTAW) 309
Gas welding
definitions 256–7
development 248–9
oxy-acetylene equipment 250
acetylene supply 250–1
assembly 256
automatic flashback arrester 254
cylinder key 255
cylinder trolley 255
gas hose 254–5
goggles 255
hose check valve 255
oxygen supply 251–2
regulators 253–4
torches 252–3
systems 249
Gases
acetylene 268
argon 266–7
argoshield 268
carbon dioxide 268
hydrogen 268
nitrogen 266
oxygen 266
propane 267–8
safety measures
acetylene cylinders 268
general storage procedures 268
oxygen cylinders 268–9
632Index
Gases (Continued)
usage/handling of cylinders
fire 269
leaks 269
ventilation/oxygen-enriched areas 270–1
Genesis electronic measuring system 433–5
Glass-Weld Pro-Vac system 471–2
Glass’s Guide Services (Glassmatrix II) 494–8
Glazing systems
direct windscreen removal/replacement 467–8
hot knife 468–70
piano wire 468
pneumatic/electric cutter 468
indirect windscreen removal/replacement 465–7
Globaljig universal bracket system 421–3
Grinder 363–4
Guillotine 170–1
Hacksaws 103–4
Hammering 358
direct 359–60
indirect (off dolly block) 360–1
removing low spots 362
roughing out damage 358–9
spring 361–2
Hammers
curved pein and finishing 87
dinging 86
engineer’s ball-pein 99
fender bumping 87
file hammer/beating file 87
hollowing/blocking 99
light bumping 85–6
mallets 87–8
pick and finishing 86–7
planishing 85
shrinking 86
standard bumping 85
straight pein and finishing 87
stretching/flanging 99
wiring 99
Hand dollies 88
curved/common block 89
double-ended 88
general-purpose 88
grid 89
heel 88
round 89
shrinking dolly block 89
thin toe 89
toe 89
utility 88
Hand grooving tools 102
Hand lever shears 169–70
Hand snips 91–2, 102–3
Hand tools 85
body files 90–1
body spoons 89–90
dollies 88–9
fabrication of sheet metal 98
hammers 85–8
hand snips 91–2
specialist panel beating tools 92–8
Hard solders
aluminium brazing 243, 245
brazing 240–2
bronze welding 245–7
silver soldering 242–3
Hardwood blocks 100
Health and safety 59, 368
electrical hazards 75
check list 75
voltages 75
fire precautions 65–70
general 72–5
legislation 75–6, 516–17
maintaining
alarm/alert/evacuation systems 81
alerting visitors 80
appropriate cleaning/sanitizing agents 83
approved/safe methods/techniques for lifting/
handling 79
availability of reports/records 82
disposal of agents 83
follow company evacuation procedure 82
guidelines, statutory regulations 76–7
identifying/removing hazards 77–8
injuries reported immediately 79–80
isolating machines/equipment 82
minimizing risk 78
people come first 80
professional emergency services 80–1
recording incidents/accidents 80
reporting immediately/accurately 78
required personal protective clothing 79
safe/approved methods for cleaning
machines/equipment 82
schedules for cleaning 83
select appropriate extinguishers 81
suppliers’/manufacturers’ instructions 78–9
use of appropriate safety clothing/
equipment 83–4
personal
ear protection 64–5
eyes and face protection 61
foot protection 61
hand protection 59
head protection 61
protective clothing 59–60
Index 633
respiratory protection 63–4
skin care 59
signs 70–1
Health and Safety at Work Act (HSWA) 76
Heat treatment
aluminium alloys 166–7
carbon steel 164–5
case hardening 166
hardening 165
normalizing 165
tempering 165–6
work hardening/annealing 163–4
High-carbon steel 128
High-strength low-alloy (HSLA) steel 125, 131
High-strength steel (HSS) 125, 130–1
cost 131
properties 131
repair 131–2
spotting 132
High-tensile steel 130
History 1–2, 8
highlights 8–10
Hot shrinking 364
aluminium 366
equipment 366
process 365–6
tools 365
Impact air screwdriver 117
Inner construction 43
Instruments, marking out, see Marking out
Insurance claims
authority to repair 491
clearance certificate 491
form 486
itemized estimate 491
Interior furnishings
carpets/floor coverings 146
fabrics 147
leather (hide) 147
modern trends 147
Jig brackets 412–13
Joining methods
adhesives 223–33
bifurcated, tubular, semitubular rivets 199
blind rivets 200–8
development 197
fastening devices 218–23
screws and bolts 211–18
solid rivets 197–9
structural fasteners 208–10
Junction 256
Korek system 408–10
Kroll Autorobot system
Autorobot L 436
III Super 437
XLS II 436–7
Lap joints 256
Latex foam 142
Legislation
Control of Substances Hazardous to Health
(COSHH) (1988) 517–21
Environment Protection Act (1990) 522–3
health and safety 516–17
Management of Health and Safety at Work
Regulations (1992) 523–4
Manual Handling Operations (1992) 525
paint storage, fire precautions, fire fighting 516
Personal Protective Equipment (PPE) at
Work (1992) 524–5
Provision and use of Work Equipment
Regulations (1992) 524
risk assessment 526–8
statutory 516
Workplace (Health, Safety and Welfare) (1992)
525–6
Light-gauge steel 306–7
Lotus Cars Ltd 546–7, 560–2
Low-carbon steel 124–5
Low spot removal 362
Lungs, see Respiratory protection
Major accident damage 405
alignment of modern integral body 438–49
concealed 405
costing/estimating
computer estimating 486
costing 483
estimating 483–6
Glassmatrix II system 494–8
insurance procedure 486, 491
motor insurance (Thatcham) 491–2
repair/replacement 482–3
replacement time schedules 492, 494
direct side 405
direct/primary 405
direction 405
front-end 405
indirect/secondary 405
parallel side 405
pulling, alignment, repair systems 406–7
Blackhawk mobile system PB30 428
car bench 419–21
Car-O-Liner systems 428–31
634Index
Major accident damage (Continued)
Celette UK 5000 pulling system 412, 413–19
Chief E-Z Liner II system 432–3
choice of systems 437–8
Dataliner 424–7
Dozer equipment 407–8
Genesis electronic measuring system 433–5
Globaljig universal bracket system 421–3
jig brackets 412–13
Korek body/frame straightening system
408–10
Kroll Autorobot multifunctional system
436–7
Mitek anchor pot collision system 410–12
Universal Bench 423–4
rear-end 405–6
repair techniques 449–52
door hanging 464–5
extensively damaged panels 463
heat barrier material 463–4
monocoque bodies by pulling 452–5
motor vehicle glazing systems 465–70
partial panel replacement 461–3
plastic repair 477–8
plastics welding 472–7
replacement of panels 457, 459–61
underbody damage of monocoque vehicles
455–6
valeting 478–82
water leak detection 470–1
wheel alignment (steering geometry) 456–7
windscreen repair 471–2
roll-over 406
three-quarter frontal 405
total write-off 406
visible 405
Mallets 99
pear-shaped 100
round-faced 100
Management of Health and Safety at Work
Regulations (1992) 523–4
Manganese steel 130
Manual Handling Operations Regulations
(1992) 525
Manual metal arc welding (MMAW) 294
accessories
cleaning tools 298
electrode holder 297
gloves 298
goggles 298
head shield/face screen 298
leather aprons 298
welding booth 298
welding earth 297–8
choice of system 297
electrical terms 295
electrodes used (BS coding) 298–9
additional coding 299
coding example 299–300
dimensions/tolerances 300
identification 300–1
strength, toughness, covering (STC) 299
equipment
AC transformers 296–7
DC generator 295–6
essential factors
correct arc length 302
correct choice of electrode 302
correct current 302–3
correct speed of travel 302
design of joint 304–6
methods of welding 303
striking the arc 303
types of joint 304
weld defects 304
welding currents 303
positions 301
flat (downhand) 301
horizontal 301
overhead 302
vertical 302
principles 294–5
safety precautions 307–8
technique
aluminium and alloys 307
light-gauge steel 306–7
mild steel plate in flat position 306
stainless steels (austenitic group only) 307
see also Gas shielded arc welding; Resistance
welding; Single-sided spot welding; Welding
Marking out 184–5
instruments
bevel gauge 188
bevel protractors 188
calipers 189–90
centre square 188–9
combination square 188
depth gauges with reversible base/protractor 190
dividers 189
drill gauge 192
feel gauges 191
gauges 190
imperial standard wire gauges 192
oddleg calipers 190
punches 187
radius gauges 192
rules 185
screw pitch gauges 191–2
scribers 185–6
straight edges 186
Index 635
trammels (beam compasses) 189
try square (engineer’s square) 187
precision instruments
engineer’s level 194
marking-off table 192–3
micrometer 195–6
surface gauge/scribing block 193–4
surface plate 193
vee blocks 194
Vernier caliper gauge 194
templates 185
Measuring instruments, see Marking out
Medium-carbon steel 128
Medium-Strength Low Alloy (MSLA) steel 131
Metal arc welding, see Manual metal arc
welding (MMAW)
Metal cutting nibbler 112
Metal flow 180
Metal-forming strength 167
angles/flanges 168
crowned surfaces 167–8
U-channels/box sections 168
Metal movement 180
Metal shaping 342–3
hollowing 343–4
planishing 348–50
puckering 343
raising 343, 344–5
split-and-weld system 348
wheeling 343, 345–8
Metal shears 110, 112
Metals
properties
compressibility 163
ductility 161–2
elasticity 163
fatigue 163
hardness 162
malleability 160–1
tenacity 162
toughness 162–3
weldability 163
Micro-alloyed steel 125, 128
MIG/MAG welding 309, 319–20
body repair work 332–3
aluminium 335
brazing 334
low-carbon steel/HSLA steels 333
preparing equipment 333
destructive testing
bend test 340
impact test 340
mechanical 339
nick-break test 340
tensile test 339–40
equipment 321–7
feed unit 325–6
gas supply 326
incorrect geometry, appearance, defects, loss
of properties
inclusions 338
lack of fusion 338
lack of penetration 338
overfill 337
porosity 338
root concavity/suck-back 337
root convexity 337
solidification cracks 338
spatter 338
underfill/undercut 337
non-destructive testing
crack detection 339
macro examination 339
magnetic particle method 339
radiography 339
ultrasonic inspection 339
positions 328–9
power unit 321–2
control panel 322–3
dip transfer (short arc) 323
free flight transfer 323
functions 322
principles of operation 320
processes
continuous weld 330
plug weld 330
spot weld 330
stitch weld 330
tack weld 329–30
quality control (BS EN ISO 9001–2000) 340
spot/plug welding 320–1
stress/distortion 335–8
residual 335–7
techniques 327–9
testing and distortion 339–40
vehicle body construction 331–2
visible examination 339
welding torch 325
welding wire 326–7
Mild steel 263, 306
Mini sheet metal cutter 104
Minor accident damage
aluminium panels 390–8
body electrical/electronic systems
398–403
body jack 372–80
body panels 380–90
body soldering 367–8
chemically hardening fillers 368–72
cold shrinking 366–7
636Index
Minor accident damage (Continued)
edge stiffening of sheet metal 353–6
fabrication of hand-made panels 350–3
filling 362–3
hammering techniques 358–62
hot shrinking 364–6
panel beating by hand 342
rectification techniques 356–8
safety points 368
sanding/disc grinding 363–4
shaping metal by hand 342–50
Mitek system 410–12
Monodex cutters 103
Motor Insurance Repair Research Centre (Thatcham)
491–2
Moulded laminates
common faults 567
blisters 570
cracking, shrinking, discolouring 571
crazing 570
fibre pattern 570
fish eyes 570
internal dry patches 571
leaching 571
low-rigidity laminate 571
pin-holing 569
poor adhesion of gel coat resin 569
star cracking 570
wrinkling 567–9
Mudguards 2
Nibbler 112
Nibbling machines 170
Non-corrosive fluxes 237–8
olive oil 238
resin and linseed oil 238
tallow and palm oil 238
Nuts 216
aerotight 216–17
captive 218–20, 221–3
castellated and slotted 216
cleveloc self-locking 217
clinch 216
flange 217
grip 220
hexagonal plain 216
lock 216
nyloc self-locking 217
spire speed 218
Outer construction 43
Oxy-acetylene equipment 250–6
Pad 256
Paint, see Spray painting
Paint shop
movement of vehicles 621
manually 621
mobile hydraulic jacks 621
rail and bogie system 621
turntable 621
under own power 621
Panel assembly terminology 51–2
Panel beating
by hand 342
elastic blow 342
floating blow 342
solid blow 342
Panel beating tools
bendable file 95
body trim tool 94
clamps 95
cobalt drills/spot drills 94
cone drills/variable hole cutters 93
corrosion assessment tool 95
door handle spring clip removers 94
door hinge pin remover/replacer 94
door skinner 96
edge setters 95–6
impact driver 94
inter-grip welding clamp 96–7
panel puller 92–3
punches 95
temporary sheet metal fastener system 97
trim panel remover 94
zipcut spot-weld remover 93
Parent metal 256
Peel test 287
Personal Protective Equipment (PPE) at
Work Regulations (1992)
524–5
Plasma arc cutting
methods 274
contact 274
distance 274
process advantages 274–5
process/equipment 271–2
high-output units 272
medium-output units 273
safety
compressed air 275
fire 275
general 275
glare and burns 275
ventilation, fumes, vapours 275
setting up equipment 273–4
Plastic fillers 368, 370–2
Index 637
Plastics
abbreviations 153
amorphous/crystalline 150
applications 150, 152
development 148
future 151, 153
identification markings 154
manufacturing processes 154–5
mechanical properties 149
painting 156
polymerization 148
reinforcement 154
repair 155–6
safety 155
thermoplastics/thermosetting 148, 150
types 153–4
Plastics welding 472–4
defects 477
charred weld 477
poor penetration/bonding 477
uneven bead width 477
warping 477
equipment 474–5
identification 474
thermoplastic 474
thermosetting 474
repair method 475–6
Pneumatic metal shear 112
Polishing machines 598, 600
Polymers 148
physical properties 149
Power drills
cordless 114
specialized air drill (spot-weld remover) 114
standard 113
Power saw 113
Power tools 109–10
Pre-impregnated material (pre-preg) 558–9
core materials 559
curing 559
foam 559
heat 560
honeycomb 559
Precision instruments, marking out, see Marking out
Production
full-size models 21–3
scale models 21
Prototypes 24
testing 24–7
Provision and use of Work Equipment
Regulations (1992) 524
Punches
hole 95
wing 95
Quality management (BS EN ISO 9001–2000)
benefits 529
bodyshop action plan 529
consultants 530
implementation/assessment 530
requirements 528–9
Ratchet wrench 117
Rear quarter panel/tonneau 49
Rear wheel arch 49
Refinishing 602
acrylic lacquer 605
complete respray from pretreated bare metal
605–6
complete respray over existing finish
local repair 606
cellulose synthetic
bare metal 603–4
local repair 604–5
over existing finish 604
coach finish 602–3
low-bake enamels 608
advantages 612
developments 612
equipment 608–9
finishing 611–12
preparation for stoving 609
preparatory work 609
spraying 609
stoving 610–11
metallic finishes 606–8
quick air drying synthetics 608
short-wave infrared paint drying 612–13
two-pack paint system 613–14
water-based paint 614
Refinishing materials
abrasive papers 580–1
burnishing
compound 581
mutton cloth 581
fillers and levellers
filler 580
stopper 580
surfacer 580
finish 580
masking
paper 581
tape 581
primers 579
etch primer 579
primer filler 579–80
638Index
Refinishing materials (Continued)
sealers
bleed-inhibiting 580
isolating 580
standard 580
solvents 581–2
Reinforced composite materials
applications 538–9
basic principles 533–4
body production in plastic (Lotus) 560–2
common faults in moulded laminates 567–71
designing for strength 547, 549–50
composite theory 550–1
fabric types and constructions 551–6
pre-impregnated material (pre-preg) 556–60
reinforcing fibres 551
resin 551
development 532–3
manufacture 534–6
moulding techniques
contact 542–5
hot press 546
production processes 546–7
spray-up technique 545–6
repair 562
accident damage assessment 562–3
accident repair 563
blind panel 566
body scratch or gash 565–6
damaged wing 563–5
important points 566–7
replacing part components 566
resins 539–40
adhesives used with GRP 542
catalysts and accelerators 540
core materials 542
fillers and pigments 541
formers 542
pre-accelerated 540–1
releasing agents 541–2
safety precautions 572
fire hazards 573
operating 572
spillage and disposal 572–3
storage 572
workshop conditions 572
types
carbon fibre 539
chopped strand mat 536–7
chopped strands 537
needle mat 537
rovings 537
staple fibres 537
woven fabrics 536
Repainting preparation 600
abrasive paper 601
paint remover 600–1
treatment with phosphating liquid 602
Repair work
aluminium
contamination 392
dent repair 396
differences 390
galvanic corrosion 392
heat application 394
heating 394
miracle repairs 396–8
oxidation 394
riveting 394
temperature measurement 394, 396
body panels
major accident 381
minor accident 380–1, 382
rust damage 381–2
bonnets 386–7
door panels 383
electrical/electronic systems 398
SAE J1930 399–402
safety check 402–3
terminology 398–9
pulling out double skin panel damage
reinforced composite materials 562–7
removal/replacement of exterior/interior
soft/hard trim 387
door 387
floor carpet 390
headlinings 390
quarter panel 390
reskinning door panels
final cleaning/inspection 386
fitting 385
preparing door flanges 385
preparing new surfaces 385
removal 383, 385
welding 385
sill panels 387
using adhesives 387
wings 383
Reporting of Injuries, Diseases and Dangerous
Occurrences Regulations (RDDOR)
75–6
Resistance welding 277–8
ARO Spotrite Pulsa system 287–90
body repair work 282
butt 281–2
electrical circuit 278
electrodes 278
Index 639
factors affecting quality 286
clearance between surfaces 286
corrosion prevention 286
destructive testing (peel test) 287
inspection of spot welds 286–7
metal surface to be welded 286
minimum welding pitch 286
positioning of welding spot from edge/
end of panel 286
flash 281
frame 278
principal forms 278
projection 280
seam 280–1
spot welding 279–80
spot welding of high-strength steels 282, 284
electrodes 285–6
heat application 285
heat balance 285
quality 284–5
timing control 278
see also Gas shielded arc welding; Manual metal arc
welding (MMAW); Single-sided spot welding;
Welding
Respiratory protection 63
cartridge filter mask 63–4
constant-flow air line breathing apparatus 64
dust masks 63
power respirators 64
Risk assessment 526–8
Rivet sets 102
Rivets
bifurcated, tubular, semitubular 199
blind 200–8
solid 197–8
Rolling machines
bending 173
cone 174
pinch 173–4
pyramid 174
safety measures 175
Roof panel 47, 49
Rubber
natural 141
synthetic 141–2
weathering 141
Rust-proofing 616
materials 617
process 618
door panels and rear quarter panels 618
engine compartment 618
pillars 618
sill panels and underbody sections 618
wheel arches and underbody 618–20
spray nozzles
flexible lance 617
hook nozzle 617
rigid lance 616–17
rules foe selection 617
straight nozzle 617
Safety 16–19, 21
primary/active 17
secondary/passive 17
see also Health and safety
Safety glass 156
adhesive systems 158
crossbreeds 157–8
laminated 157, 158
standards 157
toughened 157
vinyl interlayer 157
Sandbags 100
Sanding machines 598–600
belt 115
disc 114–15, 364
dual-action 115
geared orbital sander/polisher 116
oscillating 116–17
pneumatic sander/filler 115
rotex 117
small angle grinder 116
supa-sander (miniature belt) 117
Screwdrivers 108
Phillips (cross-heads) 19
Pozidriv 109
speciality 109
standard (slotted heads) 108–9
Torx 109
Screws
coach screws 215
machine 216
metal (self-tapping) 211, 213–14
screw nails 214–15
steel hammer drive screws 214
wood 211
Sealers 142, 144, 145
Semi-crystalline plastics 150
Shearing theory 169
Sheet metal bench stakes 100–2
anvil 100
ball 102
beck iron 102
funnel 100
grooving 100
half-moon 102
hatchet 102
640Index
Sheet metal bench stakes (Continued)
horse stake with heads 102
panel head 102
pipe 100
round-bottom 102
side 102
tinman’s mandrel 102
Sheet metal cutting
press work
blanketing 182
cut-off 182
parting 182
shearing 182
Sheet metal fabrication 169
Sheet metal folder 104
Shrinker/stretcher machine 105
Shrinking, see Cold shrinking; Hot shrinking
Silicon-manganese steel 130
Silver soldering 242–3, 244
process 243
solders and fluxes 243
Single-sided spot welding 290
equipment 290
carbon shrinking for over stretched panels 291
copper shrinking of high spots 291
pulse control roller 290
rapid puller 291
setting up 292
two-electrode 290
welding captive nuts to vehicle 292
welding copper ring washers for pulling 291
see also Gas shielded arc welding; Manual metal arc
welding (MMAW); Resistance welding; Welding
Single Vehicle Approval (SVA) scheme 52–7
Society of Automotive Engineers (SAE) 399
Socket sets 107–8
Soft solders 236
fluxes 237–8
process 238–9
apply soldering iron 239–40
choose right materials 239
clean soldering iron 239
clean surface of workpiece 239
heat soldering iron 239
reheat the bit 239
tin the soldering iron 239
varieties 236
Soldering tools 238
Solders
hard 240–7
soft 236–40
Solid rivets 197–9
dimensions 198
holes 197–8
types of joint 198–9
Sound deadening 144–6
Spanners 106
combination 106
open-ended 106
ring 106
Spray guns 584
basic parts
air cap 587
air valve 590
fluid control screw 590
fluid needle 590
fluid tip 590
gun body 590
spreader control 590
trigger 590
bleed methods 586–7
high-volume low-pressure
(HVLP) 587
maintenance and cleaning
gravity-feed gun 590
lubrication 592
pressure-feed gun 590–2
suction-feed gun 590
mix methods
external 586
internal 586
motion study 592
curved surfaces 593
external corners 593
flat surfaces 592–3
internal corners 594
sequence 594–5
paint supply methods
gravity-feed 584–5
pressure-feed 585–6
suction-feed 584
spraying defects 595
air leakage 597
compressing overheating 598
faulty packing 597
faulty patterns 596–7
fluttering 595–6
oil in air line 597
paint leakage 597
spray fog 597
Spray painting
air duster 576
air pressure 576
air receiver 576
atomization 576
colour mixing and matching
624–5
hints 625
identifying particular colour
Index 641
composition
additives 577
binder 577
pigments 577
thinner 577
defects
blistering 622
blooming 622
blushing 622
bridging 623
cobwebbing 623
dry spray 623
excessive overspray 623
lifting 623
orange peel 623
pin-holing 623
runs, sags, curtains 624
shelving 624
double-header coating 576
dry coating 576
equipment
air compressor 582–3
air hose 584
air lines 583
air transformer 583
feather edging 576
feathering the gun 576
flash off 576
fluid cap 576
fluid nozzle 576
ground coats 576
guide coat 576
hold-out 576
hot vs cold 620–1
matt finish 576
shrinkage 576
sinkage 576–7
tacking off 577
terms, air delivery 576
types
blacking 578
cellulose synthetic 577
low-bake finishes 579
oil 577
stoving 577–8
synthetic 577
two-pack 578–9
viscosity 577
Stainless steel 132–3, 264, 307
austenitic 133
austenitic/ferritic duplex 133
ferritic 133
Steel
annealing 122–3
casting 122
finishing 123
material grades, chemical compositions,
types 126–7
pickling, cold rolling steel 122
specifications 123–4
temper rolling 123
Steering 2
Structural fasteners 208
Avdelok system 209
avtainer system 210
monobolt system 210
threaded inserts 209–10
Swaging machines 176–8
Swaging tool 105
T-joints 256
Tailgate 50
Testing
engine 23
impacts 29–30
prototypes 24–7
Thatcham 491–2
Thermal insulating 144–6
Thermoplastics 148, 474
engineering 148, 150
general-purpose 148
Thermosetting materials 148, 150
Throat 257
TIG welding 309
application of welding 319
equipment used 315–16
filler metals 317
gas supply 317
power unit 316
TIG electrodes 317–18
welding torch 316–17
modes of operation 313
principles of operation 312–13
spot welding 314–15
welding techniques 318–19
Toe 256
Toolchests 109
Transformation induced plasticity (TRIP) 131
Trims 51
Ultra Light Steel Auto Body (ULSB) 131
Ultra Light Steel Body–Advanced Vehicle Concepts
(ULSB–ACV) 131
Underbody 46, 439–41, 442, 455–6, 618–20
Undercut 256–7
Undersealing materials 144–6
Universal Bench systems 423
bracketless 423–4
642Index
Valeting 478
cleaning process 479
checklist 482
dry bay 481–2
wet bay 479–80
premises, equipment, chemicals 478–9
Vehicle classification 11
Vehicle identification numbers (VIN) 52
Vehicle type approval 52–7
Water leak detection 470
locating 471
sealing 471
testing 471
tools/equipment 470
ultrasonic equipment 471
Weld face 256
Weld penetration 256
Welding
alloy steels 263–4
aluminium 265
aluminium castings 265
backfiring/flashbacks of torch 271
carbon steel 263
cast iron 265
equipment safety
fluxes 271
goggles 271
pressure regulators 271
protection 271
rubber hose 271
welding torch 271
methods
leftward 259
rightward/all-position rightward 259–60
mild steel 263
stainless steel 265
technique 263
see also Gas shielded arc welding; Manual metal arc
welding (MMAW); Resistance welding;
Single-sided spot welding
Welding fluxes 257
Welding rod 256, 257
Wheeling machines 175–6
Wheels 2
Windscreens 2
repairs
direct removal/replacement 467–8
Glass-Weld Pro-Vac 471–2
indirect removal/replacement 468–70
Wings 49
Workplace (Health, Safety and Welfare)
Regulations (1992) 525–6
Wrenches 106
adjustable 107
Wrought light aluminium alloys (BS specifications
1470–1475)
abbreviations for basic temper
annealed 135
as fabricated 135
abbreviations for heat-treated
materials 135
abbreviations for strain hardened
materials 135
material designations 135
Zinc coated steel 128
double-sided 128, 130
single-sided 128
Zone of thermal disturbance 256