Metal Body Repair

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Metal Body Repair

Metal Body Repair
Notice to Students
General
Table of Contents
Task 1. Describe the Operations Required to Repair Damaged Vehicles And Components.
Body and Frame Construction
Body Construction.
Figure 2. Floor Pan Assembly
Frame Construction.
Frame Construction cont.
Figure 4. Frame (Cargo, Shop Van, Tanker).
Metal Body Trim and Hardware
Figure 5. Cross-Section of Windshield Weatherstripping and Molding
Handles.
Figure 6. Types of Body And Fender Hammers.
Dollys.
Drip Molding Pliers
Cowl Bracket
File Bolder and Blade.
Metal Body Equipment
Figure 9. Hydraulic Body Jack And Attachments.
Electric Disk Sander
Sanding Disks.
Figure 10. Correct And Incorrect Methods Of Using The Electric Sander.
Comparative Measurement.
Figure 12. Diagonals Of Cubes Are Always Of Equal Lenght.
Body and Fender Repair Techniques
Roughing and Aligning
Figure 13. Using Hammer And Dolly
Figure 14. Simple Damage.
Figure 15. Removing Simple Damage Correctly.
Figure 16. Removing Simple Damage Incorrectly.
Figure 17. Tram.
Figure 18. X-Checking Frame Alignment With Tram.
Figure 19. X - Checking Door Opening Alignment With A Tram.
Figure 21. Checking Instrument Panel Alignment.
Figure 22. Checking Center - Section Alignment
Figure 24. Portable Hydraulic Jack
Hammer Finishing
Figure 25. Holding Dolly Correctly When Hammering Directly.
Indirect Hammering
Spring Hammering.
Pick Hammering.
Metal Shrinking.
Hot Shrinking.
Figure 30. Upsetting a Stretched Area for Shrinking.
Certain rules should be observed at all times during shrinking Operations
Cold Shrinking.
Figure 32. Body File.
Conclusion
Conclusion cont.
Practical Exercise 1
Practical Exercise 1 cont.
Practical Exercise 1 cont.
Practical Exercise 1 cont
Lesson 1. Practical Exercise - Answers
Lesson 1. Practical Exercise - Answers - Continued
Lesson 1. Practical Exercise - Answers - Continued
Lesson 2. Operations Required for Glass, Radiator, and Fuel Tank Repair
Glass- Composition and Characteristics
Types of Glass.
Removal of Vehicle Glass.
Glass Cutting
Glass Cutting.- Continued
Plastic Cutting.
Glass Grinding and finishing
Installing Glass.
Figure 33. Exploded View of 1.4 Winshield
Safety Precautions
Conclusion
Describe the Operations Required for Proper Radiator Repair
Figure 34. Stamped Metal Radiator
Water Tanks.
Figure 35. Radiator Construction
Radiator Cleaning.
Pressure Flushing
Testing Radiator for Leaks
Visual Inspection.
Locating Leaks
Figure 36. Test Tool for Tubular Cores.
Radiator Disassembly
Filler Neck.
Radiator Assembly.
Radiator Assembly. - Continued
Repairing Radiator Leaks
Blocking of Tubes
Straihteninga Bent Radiator
Repair Procedures for End tanks
Repair Procedures for Cores.
Conclusion
Task. Describe the Operations Required for Proper fuel Tank Repair
Figure 37. Typical Fuel Tank Construction
Figure 28. Cutaway View of Fuel Tank
Fuel Tank Fittings
Figure 39. Pressure-Type Fuel Tank Filler Cap
Fiberglass Fuel Tanks.
Cleaning
Safety Rules
Safety Rules cont.
Practical Exercise 2
First Requirement
Third Requirement
Lesson 2. Practical Exercise- Answers
Lesson 2. Practical Exercise- Answers - Continued
References
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Metal Body Repair

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