| |
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Preface | |
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About the Book | |
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Features of the Text | |
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Supplements | |
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About I-CAR | |
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Acknowledgments | |
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Fundamentals | |
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Industry Overview and Careers | |
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History Note | |
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Collision Repair Technician | |
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Other Personnel | |
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The Professional | |
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What is Collision Repair? | |
| |
| |
What is a Collision? | |
| |
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Vehicle Construction Basics | |
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Shop Operations | |
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Collision Repair Facilities | |
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| |
Summary | |
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| |
Technical Terms | |
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| |
Review Questions | |
| |
| |
ASE-Style Review Questions | |
| |
| |
Activities | |
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Safety and Certification | |
| |
| |
What Causes Accidents? | |
| |
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Types of Accidents | |
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Textbook Safety | |
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Overall Shop Safety | |
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Shop Layout and Safety | |
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In Case of an Emergency | |
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Work Area Safety | |
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Fire Safety | |
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Avoiding Falls | |
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Avoiding Electrocution | |
| |
| |
Avoiding Asphyxiation | |
| |
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Avoiding Eye Injuries | |
| |
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Avoiding Chemical Burns | |
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| |
Personal Safety | |
| |
| |
Tool and Machine Safety | |
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| |
Paint Shop Safety | |
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Respirators | |
| |
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Dustless Sanding Systems | |
| |
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Air Bag Safety | |
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Manufacturer's Warnings | |
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Right-to-Know Laws | |
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Employer Responsibilities | |
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Waste Disposal | |
| |
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Liability | |
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Technician Liability | |
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| |
ASE Certification | |
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| |
I-CAR | |
| |
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Don't Be Foolish! | |
| |
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Summary | |
| |
| |
Technical Terms | |
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Review Questions | |
| |
| |
ASE-Style Review Questions | |
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Activities | |
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| |
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Vehicle Construction | |
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Crash Testing | |
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Vehicle Classifications | |
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Vehicle Construction | |
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Joining Parts | |
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Major Body Sections | |
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Panel and Assembly Nomenclature | |
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Front Section Parts | |
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Center Section Parts | |
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Rear Section Parts | |
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Gaskets and Seals | |
| |
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Anticorrosion Materials | |
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Sound-Deadening Materials | |
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Engine Locations, Drive Lines | |
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Vehicle Sizes | |
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Roof Designs | |
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Vans and Trucks | |
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Summary | |
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Technical Terms | |
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Review Questions | |
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ASE-Style Review Questions | |
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Activities | |
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Hand Tools | |
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| |
Purchase Quality Tools | |
| |
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Tool Storage | |
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| |
General Duty Hammers | |
| |
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Body Hammers | |
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Dollies and Spoons | |
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Holding Tools | |
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Punches and Chisels | |
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Wrenches | |
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Wrench Types | |
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Pry Bars | |
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| |
Screwdrivers | |
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Pliers | |
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| |
Sheet Metal Tools | |
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| |
Files | |
| |
| |
Saws | |
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| |
Cleaning Tools | |
| |
| |
Creepers, Covers | |
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Hydrometers | |
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Fluid Handling Tools | |
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| |
Tire Tools | |
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Pullers, Picks | |
| |
| |
Miscellaneous Collision Repair Tools | |
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| |
Summary | |
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| |
Technical Terms | |
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| |
Review Questions | |
| |
| |
ASE-Style Review Questions | |
| |
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Activities | |
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Power Tools and Equipment | |
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| |
Air Supply System | |
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Air Compressor | |
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Air Lines | |
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Air Pressure Regulator and Filter | |
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Air Tools | |
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Grinders | |
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| |
Polishers | |
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Pneumatic Tool Maintenance | |
| |
| |
Blasters | |
| |
| |
Spray Guns | |
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Spray Booths | |
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Paint Drying Equipment | |
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Measuring Systems | |
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Straightening Systems | |
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Lifts | |
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| |
Electric Tools | |
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Battery Charger | |
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Multimeter | |
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Scan Tools | |
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Engine Analyzer | |
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Personal Computer | |
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Soldering Gun | |
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Plastic Welder | |
| |
| |
Air Conditioning Tools | |
| |
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Other Equipment | |
| |
| |
Summary | |
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Technical Terms | |
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Review Questions | |
| |
| |
ASE-Style Review Questions | |
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| |
Activities | |
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Basic Measurement and Service Information | |
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SAE and Metric Systems | |
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Conversion Charts | |
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Linear Measurements | |
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Scales | |
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Dividers and Calipers | |
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Micrometers | |
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Dial Indicators | |
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Feeler Gauges | |
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Pressure and Flow Measurements | |
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Angle Measurements | |
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Temperature Measurements | |
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Paint-Related Measurements | |
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Paint Mixing Sticks | |
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Viscosity Cup Measurement | |
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Paint (Material) Thickness Measurement | |
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Vehicle Identification Number (VIN) | |
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Collision Repair Publications | |
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Computerized Service Information | |
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Color Matching Manuals | |
| |
| |
Summary | |
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| |
Technical Terms | |
| |
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Review Questions | |
| |
| |
ASE-Style Review Questions | |
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| |
Activities | |
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| |
Fasteners | |
| |
| |
Bolts | |
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| |
Nuts | |
| |
| |
Thread Repair | |
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| |
Washers | |
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Screws | |
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| |
Nonthreaded Fasteners | |
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| |
Replacing Fasteners | |
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| |
Hose Clamps | |
| |
| |
Adhesives | |
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| |
Summary | |
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| |
Technical Terms | |
| |
| |
Review Questions | |
| |
| |
ASE-Style Review Questions | |
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Activities | |
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Collision Repair Hardware and Materials | |
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| |
Refinishing Materials | |
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| |
Undercoats and Topcoats | |
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| |
Paint Types | |
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| |
Original Equipment Manufacturer (OEM) Finishes | |
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| |
Contents of Paint | |
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| |
Drying and Curing | |
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| |
Primers and Sealers | |
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| |
Sealers | |
| |
| |
Primer-Surfacers | |
| |
| |
Use a Complete System! | |
| |
| |
Other Paint Materials | |
| |
| |
Body Fillers | |
| |
| |
Glazing Putty/Finishing Fillers | |
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| |
Masking Materials | |
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| |
Abrasives | |
| |
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Grinding Discs | |
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| |
Sandpapers | |
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| |
Scuff Pads | |
| |
| |
Compounds | |
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| |
Adhesives | |
| |
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Epoxies | |
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Sealers | |
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| |
Hazardous Materials | |
| |
| |
Waste Disposal and Recycling | |
| |
| |
Summary | |
| |
| |
Technical Terms | |
| |
| |
Review Questions | |
| |
| |
ASE-Style Review Questions | |
| |
| |
Activities | |
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| |
| |
Welding, Heating, and Cutting | |
| |
| |
What is Welding? | |
| |
| |
Weld Terminology | |
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| |
Welding Categories | |
| |
| |
Metal Inert Gas (MIG) Welding | |
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| |
Welding Positions | |
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| |
Welding Safety | |
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Welding Surface Preparation | |
| |
| |
Holding Parts | |
| |
| |
Weld-Through Primer | |
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| |
Using the MIG Welder | |
| |
| |
MIG Burnback | |
| |
| |
Wire Speed | |
| |
| |
Shielding Gas Flow Rate | |
| |
| |
Heat Buildup Prevention | |
| |
| |
Clean After Welding | |
| |
| |
Resistance Spot Welding | |
| |
| |
Weld Problems | |
| |
| |
Welding Aluminum | |
| |
| |
Oxyacetylene Welding | |
| |
| |
Plasma Arc Cutting | |
| |
| |
Summary | |
| |
| |
Technical Terms | |
| |
| |
Review Questions | |
| |
| |
ASE-Style Review Questions | |
| |
| |
Activities | |
| |
| |
| |
Minor Repairs | |
| |
| |
| |
Straightening Fundamentals | |
| |
| |
Sheet Metal | |
| |
| |
Steel Strength | |
| |
| |
Physical Structure of Steel | |
| |
| |
Effect of Impact Forces | |
| |
| |
Work Hardening | |
| |
| |
Kinds of Damage | |
| |
| |
Using Body Hammers | |
| |
| |
Straightening with Dollies | |
| |
| |
Hammer-on-Dolly | |
| |
| |
Hammer-off-Dolly | |
| |
| |
Straightening with Spoons | |
| |
| |
Straightening with Picks | |
| |
| |
Pulling Damaged Areas | |
| |
| |
Shrinking Metal | |
| |
| |
Identifying Stretched Metal | |
| |
| |
Filing the Repair Area | |
| |
| |
Working Aluminum | |
| |
| |
Using Body Filler | |
| |
| |
Preparing Surface for Filler | |
| |
| |
Summary | |
| |
| |
Technical Terms | |
| |
| |
Review Questions | |
| |
| |
ASE-Style Review Questions | |
| |
| |
Activities | |
| |
| |
| |
Plastic and Composite Repair | |
| |
| |
Types of Auto Plastics | |
| |
| |
Plastics Safety | |
| |
| |
Plastic Identification | |
| |
| |
Plastic Part Removal | |
| |
| |
Principles of Plastic Welding | |
| |
| |
Hot-Air Plastic Welding | |
| |
| |
Airless Plastic Welding | |
| |
| |
Plastic Welding Methods | |
| |
| |
Hot-Air Plastic Welding Procedure | |
| |
| |
Plastic Tack Welding | |
| |
| |
Welding a Plastic V-Groove | |
| |
| |
Plastic Speed Welding | |
| |
| |
Airless Melt-Flow Plastic Welding | |
| |
| |
Plastic Stitch-Tamp Welding | |
| |
| |
Single-Sided Plastic Welds | |
| |
| |
Two-Sided Plastic Welds | |
| |
| |
Repairing Vinyl Dents | |
| |
| |
Welding Vinyl-Foam Cuts | |
| |
| |
Heat Reshaping Plastic Parts | |
| |
| |
Plastic Bumper Tab Replacement | |
| |
| |
Plastic Adhesive Repair Systems | |
| |
| |
Use the Correct Adhesive! | |
| |
| |
Two-Part Plastic Adhesive Repairs | |
| |
| |
Two-Part Adhesive Dash Repair | |
| |
| |
Reinforced Plastic Repairs | |
| |
| |
Reinforced Plastic Adhesives | |
| |
| |
Reinforced Plastic Fillers and Glass Cloth | |
| |
| |
Reinforced Plastic, Single-Sided Repairs | |
| |
| |
Two-Sided Repairs of Reinforced Plastic | |
| |
| |
Using Molded Cores | |
| |
| |
Repairing RRIM | |
| |
| |
Spraying Vinyl Paints | |
| |
| |
Summary | |
| |
| |
Technical Terms | |
| |
| |
Review Questions | |
| |
| |
ASE-Style Review Questions | |
| |
| |
Activities | |
| |
| |
| |
Replacing Hoods, Bumpers, Fenders, Grilles, and Lids | |
| |
| |
How are Parts Fastened? | |
| |
| |
Refer to Estimate | |
| |
| |
Where to Start | |
| |
| |
Hood Removal and Replacement | |
| |
| |
Bumper Removal, Replacement, and Adjustment | |
| |
| |
Fender Removal, Replacement, and Adjustment | |
| |
| |
Grille Removal and Replacement | |
| |
| |
Deck Lid Removal, Replacement, and Adjustment | |
| |
| |
Panel Alignment | |
| |
| |
Truck Bed Removal and Replacement | |
| |
| |
Installing Sound-Deadening Pads | |
| |
| |
Summary | |
| |
| |
Technical Terms | |
| |
| |
Review Questions | |
| |
| |
ASE-Style Review Questions | |
| |
| |
Activities | |
| |
| |
| |
Servicing Doors, Glass, and Leaks | |
| |
| |
Doors | |
| |
| |
Door Construction | |
| |
| |
Door Adjustments | |
| |
| |
Glass | |
| |
| |
Air and Water Leaks | |
| |
| |
Rearview Mirror Service | |
| |
| |
More Information | |
| |
| |
Summary | |
| |
| |
Technical Terms | |
| |
| |
Review Questions | |
| |
| |
ASE-Style Review Questions | |
| |
| |
Activities | |
| |
| |
| |
Prepainting Preparation | |
| |
| |
| |
Vehicle Surface Preparation | |
| |
| |
Vehicle Cleaning | |
| |
| |
Surface Evaluation | |
| |
| |
Chemical Stripping | |
| |
| |
Blasting Paint | |
| |
| |
Removing Paint | |
| |
| |
Bare Metal Treatment | |
| |
| |
Preparing Metal Replacement Parts | |
| |
| |
Sanding | |
| |
| |
Featheredging | |
| |
| |
Undercoat Systems | |
| |
| |
Using Spot Putty | |
| |
| |
Using a Guide Coat | |
| |
| |
Masking | |
| |
| |
Summary | |
| |
| |
Technical Terms | |
| |
| |
Review Questions | |
| |
| |
ASE-Style Review Questions | |
| |
| |
Activities | |
| |
| |
| |
Shop and Equipment Preparation | |
| |
| |
Painting Environment | |
| |
| |
Preparing Spray Booth | |
| |
| |
Mixing and Storage Area Prep | |
| |
| |
Preparing Spray Equipment | |
| |
| |
Mixing Paint and Solvent | |
| |
| |
Viscosity | |
| |
| |
Paint Temperature | |
| |
| |
Captive Spray Gun System | |
| |
| |
Summary | |
| |
| |
Technical Terms | |
| |
| |
Review Questions | |
| |
| |
ASE-Style Review Questions | |
| |
| |
Activities | |
| |
| |
| |
Refinishing | |
| |
| |
| |
Painting and Refinishing Fundamentals | |
| |
| |
Preparation Review | |
| |
| |
Review of Topcoats | |
| |
| |
Determining Type of Finish | |
| |
| |
Spray Gun Application Stroke | |
| |
| |
Paint/Material Thickness Measurement | |
| |
| |
Gun Handling Problems | |
| |
| |
Types of Spray Coats | |
| |
| |
Paint Blending | |
| |
| |
Refinishing Methods | |
| |
| |
Spot Repairs | |
| |
| |
Panel Repairs | |
| |
| |
Overall Refinishing | |
| |
| |
Applying Basecoat-Clearcoat | |
| |
| |
Applying Tri-Coat Finishes | |
| |
| |
Refinishing Rules | |
| |
| |
Removal of Masking Materials | |
| |
| |
Finishing Rigid Exterior Plastic Parts | |
| |
| |
Finishing Polypropylene Parts | |
| |
| |
Finishing Urethane Bumpers | |
| |
| |
Cleaning the Spray Gun | |
| |
| |
Spray Gun Cleaning Steps | |
| |
| |
VOC Tracking | |
| |
| |
Summary | |
| |
| |
Technical Terms | |
| |
| |
Review Questions | |
| |
| |
ASE-Style Review Questions | |
| |
| |
Activities | |
| |
| |
| |
Color Matching | |
| |
| |
Color Theory | |
| |
| |
Lighting | |
| |
| |
Color Blindness | |
| |
| |
Dimensions of Color | |
| |
| |
Metamerism | |
| |
| |
Plotting Color | |
| |
| |
Color Matching | |
| |
| |
Paint Formulas | |
| |
| |
Spectrophotometer | |
| |
| |
Computerized Color Matching Systems | |
| |
| |
Color Variance Programs | |
| |
| |
Spray Methods Affect Color | |
| |
| |
Matching Solid Colors | |
| |
| |
Matching Metallic Finishes | |
| |
| |
Matching Multi-Stage Finishes | |
| |
| |
Zone Concept | |
| |
| |
Color Flop | |
| |
| |
Checking Color Match | |
| |
| |
Blending Clearcoats | |
| |
| |
Fluorine Clearcoat Repairs | |
| |
| |
Tri-Coat Spot Repair | |
| |
| |
Tri-Coat Panel Repair | |
| |
| |
Blending Mica Coats | |
| |
| |
Matching Mica Colors | |
| |
| |
Why a Color Mismatch? | |
| |
| |
Tinting | |
| |
| |
Summary | |
| |
| |
Technical Terms | |
| |
| |
Review Questions | |
| |
| |
ASE-Style Review Questions | |
| |
| |
Activities | |
| |
| |
| |
Paint/Refinish Problems and Final Detailing | |
| |
| |
Surface Imperfections | |
| |
| |
Surface Finish Measurements | |
| |
| |
Paint Problems | |
| |
| |
Final Detailing | |
| |
| |
Get Ready | |
| |
| |
Caring for New Finish | |
| |
| |
Summary | |
| |
| |
Technical Terms | |
| |
| |
Review Questions | |
| |
| |
ASE-Style Review Questions | |
| |
| |
Activities | |
| |
| |
| |
Decals, Custom Painting, and Trim | |
| |
| |
Overlays and Tape Stripes | |
| |
| |
Painted Pinstripes | |
| |
| |
Custom Painting | |
| |
| |
Moldings and Trim | |
| |
| |
Summary | |
| |
| |
Technical Terms | |
| |
| |
Review Questions | |
| |
| |
ASE-Style Review Questions | |
| |
| |
Activities | |
| |
| |
| |
Major Repairs | |
| |
| |
| |
Measuring Vehicle Damage | |
| |
| |
Why is Measurement Important? | |
| |
| |
Damage Diagnosis | |
| |
| |
Safety | |
| |
| |
Impact Effects | |
| |
| |
Analyzing Collision Forces | |
| |
| |
Types of Frame Damage | |
| |
| |
Unibody Vehicle Damage | |
| |
| |
Dimensional References | |
| |
| |
Vehicle Measuring Basics | |
| |
| |
Types of Measuring Equipment | |
| |
| |
More Information | |
| |
| |
Summary | |
| |
| |
Technical Terms | |
| |
| |
Review Questions | |
| |
| |
ASE-Style Review Questions | |
| |
| |
Activities | |
| |
| |
| |
Straightening Full-Frame and Unibody Vehicles | |
| |
| |
Alignment Basics | |
| |
| |
Straightening Equipment | |
| |
| |
Measure As You Pull! | |
| |
| |
Part Removal | |
| |
| |
Planning the Straightening | |
| |
| |
Straightening Safety | |
| |
| |
Straightening Basics | |
| |
| |
Anchoring Procedures | |
| |
| |
Wheel Clamps | |
| |
| |
Attaching Pulling Chains | |
| |
| |
Executing a Planned Straightening Sequence | |
| |
| |
Straightening Directions | |
| |
| |
Overpulling | |
| |
| |
Aligning Front End Damage | |
| |
| |
Rear Damage Repairs | |
| |
| |
Straightening Side Damage | |
| |
| |
Straightening Sag | |
| |
| |
Straightening Diamond Damage | |
| |
| |
Stress Relieving | |
| |
| |
Stress Concentrators | |
| |
| |
Final Straightening/Alignment Checks | |
| |
| |
Summary | |
| |
| |
Technical Terms | |
| |
| |
Review Questions | |
| |
| |
ASE-Style Review Questions | |
| |
| |
Activities | |
| |
| |
| |
Other Operations | |
| |
| |
| |
Replacing Structural Parts and Corrosion Protection | |
| |
| |
Repair or Replace Guidelines | |
| |
| |
Types of Structural Replacements | |
| |
| |
Determining Spot Weld Locations | |
| |
| |
Separating Spot Welds | |
| |
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Separating Continuous Welds | |
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Preparing Vehicle for New Panel | |
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Preparing Replacement Panel/Part | |
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Positioning New Panels | |
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Welding New Panels/Parts | |
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Sectioning | |
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Corrosion | |
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Summary | |
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Technical Terms | |
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Review Questions | |
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ASE-Style Review Questions | |
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Activities | |
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Interior Repairs | |
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Seat Service | |
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Carpeting Service | |
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Headliner Service | |
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Instrument Panel Service | |
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Instrument Cluster Service | |
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Summary | |
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Technical Terms | |
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Review Questions | |
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ASE-Style Review Questions | |
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Activities | |
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Mechanical Repairs | |
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Powertrain | |
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Engine Support Systems | |
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Drivetrain | |
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Steering Systems | |
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Suspension Systems | |
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Air Conditioning Systems | |
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Emission Control Systems | |
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Summary | |
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Technical Terms | |
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Review Questions | |
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ASE-Style Review Questions | |
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Activities | |
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Wheel Alignment | |
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Wheel Alignment Basics | |
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Prealignment Checks | |
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Diagnostic Checks | |
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Wheel Alignment Procedures | |
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Alignment Equipment Variations | |
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Road Test After Alignment | |
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Summary | |
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Technical Terms | |
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Review Questions | |
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ASE-Style Review Questions | |
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Activities | |
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Electrical Repairs | |
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Electrical Terminology | |
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Diagnostic Equipment | |
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Wiring Diagrams | |
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Electric Components | |
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Circuit Protection Devices | |
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Fuses | |
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Fuse Links | |
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Circuit Breakers | |
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Electrical-Electronic Systems | |
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Electrical Problems | |
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Batteries | |
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Lighting and Other Electric Circuits | |
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Repairing Wiring and Connections | |
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Solder Repair | |
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Electrical Connector Service | |
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Computer Systems | |
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Scanning Computer Problems | |
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Protecting Electronic Systems | |
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Summary | |
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Technical Terms | |
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Review Questions | |
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ASE-Style Review Questions | |
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Activities | |
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Restraint System Repairs | |
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Active and Passive Restraints | |
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Seat Belt Systems | |
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Child Restraint Systems and Air Bag Safety | |
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Air Bag Systems | |
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Summary | |
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Technical Terms | |
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Review Questions | |
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ASE-Style Review Questions | |
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Activities | |
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Estimating and Entrepreneurship | |
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Estimating Repair Costs | |
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Damage Analysis | |
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Direct and Indirect Damage | |
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Vehicle Inspection | |
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Interior Inspection | |
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Damage Quick Checks | |
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Dimension Manuals | |
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Collision Estimating Guides | |
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Damage Report Terminology | |
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Part Costs | |
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Writing Estimates | |
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Estimating Sequence | |
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Flat Rate Operations | |
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Labor Costs | |
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Refinishing Time | |
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Total Labor Costs | |
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Totaling the Estimate | |
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Computerized Estimating | |
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Front Clips | |
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Sectioning | |
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Total Loss | |
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Summary | |
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Technical Terms | |
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Review Questions | |
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ASE-Style Review Questions | |
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Activities | |
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Entrepreneurship and Job Success | |
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Collision Repair Technician | |
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Related Professions | |
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Entrepreneurship | |
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Cooperative Training Programs | |
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Keep Learning! | |
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Use a Systematic Approach | |
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Work Traits | |
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Summary | |
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Technical Terms | |
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Review Questions | |
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ASE-Style Review Questions | |
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Activities | |
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Glossary | |
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Abbreviations Used by Collision Repair Technicians | |
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Measurement Equivalents | |
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Tap and Drill Bit Data | |
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Reference Tables | |
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Torque Values | |
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Index | |