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 manufacturers
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?
626 Repair 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
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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 8090 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 2234
achieving good results 228
body repair 233
classification chart 143
curing times 227
hot metals 228, 2312
joint function 227
joint types
butt 226
co-axial 226
plain lap 226
non-structural 228
selection by computer 2278
service conditions 227
surface preparation 22931
toughened structural 2323
types
anaerobics 224
cyanoacrylates 224
epoxies 2245
hot melts 225
phenolics 225
plastisols 225
polyurethanes 2256
solvent-borne rubber 226
tapes 226
toughened 226
Advanced high-strength steel (AHSS) 1312
Aerodynamics 23
drag 234
Air power chisel 110
Alignment
bonnet 446, 4489
boot lid 449
digital measuring tool 441
door 4446
misalignment and vehicle control 438
underbody
drop-line method 439
gunsight gauge method 43941
jig fixtures 442
underframe 438
upper structure 4434
Alloy steels 2634
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 1334, 264, 307, 366
manufacturing process 1345, 141
production 134
repairing 3908
types of sheet 134
Aluminium alloys 134
availability, physical properties, applications 140
chemical composition limits, mechanical
properties 1379
commonly used elements 1345
general characteristics 136
heat-treatable 134
heat treatment 1667
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 2879
setting up equipment 28990
welding procedure 290
Assembly/dismantling tools 1056
screwdrivers 1089
socket sets 1078
spanners/wrenches 1067
toolchests 109
Automotive finishing
basic composition of paint 577
burnishing, polishing, final detail work 61416
colour mixing and matching 6245
common spray painting defects 6224
history 5746
hot vs cold spraying 6201
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materials used in refinishing 57982
movement of vehicle in paint shop 621
preparation of motor vehicle 6002
refinishing processes 60214
rust-proofing 61620
Index
628 Index
Automotive finishing (Continued)
sanding and polishing machines 598600
spray guns 58495
spray painting equipment 5824
spray painting terms 5767
spraying defects 5958
types of paint 5779
Bending machines
angle bender/clamp folder 172
box/pan (universal) 173
edge folder 172
open-end folder 1723
safety measures 173
Bending theory 171
behaviour of metal 171
calculation 172
Bending tools 1045
Blackhawk PB30 system 428
Blended plastics 150
Blind rivets
POP 200
blind 204
ELF 203
grooved 202
LSR 201
MGR 2012
peel 203
special 203
standard open 2001
well nut 204
repetition 204
Briv system 206
Chobert Grovit system 2056
Chobert system 2045
selection
diameter 207
edge distance 208
hole size 207
mandrel type 208
pitch of rivets 2078
rivet length 207
rivet material 208
tools 2067
Body engineering 27
Body files
abrasive 91
body file blades 91
flat 91
flexible panel 901
Body jack (hydraulic)
application
example 3789
pulling 376
pushing 3756
spreading 3767
stretching/tensioning 3778
basic equipment 3735
care/maintenance 379
bleeding 37980
hose 380
threads on ram/attachments 380
development/principles 3723
Body pressings 4352
Body shell 51
panels 129
Body side frame 467
Body soldering 367
composition/requirements 367
process 3678
Body spoons 89
drip moulding 90
general-purpose 8990
heavy-duty pry 90
high-crowned 90
long-reach 90
pry/surfacing 90
spring hammering 90
surface 89
thin 90
Body style terminology 1011
Bodyshop planning
administration offices 503, 505, 507
choosing a site 5012
essential equipment 512
dust/fume extraction 51315
general workshop 513
hand tools/power tools 513
miscellaneous/expendable items 513
specialist stripping, repairing, painting 51213
final inspection area 505
fire fighting equipment 504, 5089
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, 51528
light sources
fluorescent tubes 512
high pressure sodium 512
mercury lamps 512
tungsten bulbs 512
lighting 510
paint mixing room 511
preparation area 51011
Index 629
spray booth/painting area 51112
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 90012000) 52830
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 5023
Bolts 215
countersunk head 215
hexagon head 215
Bonded windscreen electric cutter 119
Bonnet 501
alignment 446, 4489
repair work 3867
Boot floor 46
Boot lid 50
Boron steel 1324
Brake presses 1789
Brazing 240
advantages 242
aluminium 243, 245
bronze 2457
process 240, 242
Breathing protection, see Respiratory
protection
Bronze welding 2456
procedure 2467
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 41920
scissor-action lift 420
standard four-post lift 4201
unified support system 421
Car-O-Liner system
BenchRack 431
Mark 5 collision repair 42831
measuring 431
Carbon steel 1245, 263
heat treatment 1646
Cast iron 264
Celette UK system 412
benches 41314
Bodymaster 2000 drive-on system 41718
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ECO 2000 mobile lifting trolley 418
jig lifts 414
Metro 2000 measurement 41617
Metro 90 measurement 418
MZ system 41416
Celluloid 2
Chemically hardening fillers (plastic fillers)
368, 3702
Chief E-Z Liner II system 4323
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 3667
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) 345
semi-integral 35
Consultants 530
Control of Substances Hazardous to Health
(COSHH) Regulations (1988) 75,
767, 51721
Copper-phosphorus brazing alloys 241
Corrosive fluxes 237
hydrochloric acid 237
phosphoric acid 237
zinc chloride (killed spirits) 237
Cutting machines
guillotine 1701
hand lever shears 16970
universal shearing 170
Cutting tools
cold chisels 103
drill attachment 104
hacksaws 1034
hand snips 1023
mini sheet metal 104
monodex cutters 103
630 Index
Damage rectification 3568
Dataliner repair system 424
drive-on rack 426
laser check 4267
measuring 4245
straightening equipment 4256
Design
computer-aided 15
concept to realization 1432
ergonomics 16
evolution 11, 14
stages 15
styling 1516
Dismantling tools, see Assembly/dismantling
tools
Distortion control 2603
Doors 4950
Dozer equipment 4078
Drawing operations 1802
box 180, 182
cupping 180
panel 182
Drill cutting attachment 104
Dual phase (DP) steel 131
Duramix 4778
Dust extraction 11920
Edge joint 256
Edge preparation 260
control of distortion 2603
Edge setter 105
Edge treatment 3534
flanging 3545
folding 354
swaging 3556
wiring 356
Electrical and electronic systems 398
airbags 401
alternator 400
battery 400
central locking 400
control unit 4012
electric seat 4001
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 3989
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) 5223
EuroNCAP 2730
Fabrication of hand-made panels 3503
Fabrication tools
hammers 989
mallets 99100
Fasteners
Christmas-tree buttons 222
D type edge fasteners 223
push-in panel (W-buttons) 222
quick-release 223
snapsacs 223
trim panel 2223
Fastening devices
cable clip 220
captive nut, J type 21920
captive nut, U type 21819
non-metal clips 221
nut grip 220
plastic captive nuts/trim panel fasteners 2212
push-on clips 221
spire speed nut 218
Index 631
Filler rods 257
Fillet welds 256
Filling 3623
Fire
gas cylinders 269
plasma arc cutting 275
reinforced composite materials hazards 573
Fire precautions
definition of fire 667
general 68
methods of extinction 67
removal of fuel 67
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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 678
body filler 68
class A: wood, paper, cloth 67
class B: flammable liquids 67
class C: gases 67
electrical hazards 678
Flame control
adjustment/gas pressure 258
power of flame 258
temperature 257
carbonizing, carburizing, reducing 2578
natural flame 258
oxidizing flame 258
Flexible polyurethane 142
Floor (main) 46
Fluid dynamics
Ahmed model 32
calculations 312
definition 301
grid system 32
Reynolds Number 31
Fluxes 2378, 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 2356
total 235
Fusion face 256
Fusion zone 256
Gas cutting 264
flame 264
hand cutting procedure 266
machine 266
nozzles 2656
torch 2645
Gas metal arc welding (GMAW) 309
Gas shielded arc testing, equipment maintenance/safety
3401
Gas shielded arc welding
development 309
gases used 31011
argon 311
argon mixtures 312
carbon dioxide 31112
choice 312
helium 311
helium mixtures 312
metal active gas (MAG) 309, 31938
metal inert gas (MIG) 309, 31938
tungsten inert gas (TIG) 309,
31219
see also Manual metal arc welding (MMAW);
Resistance welding; Single-sided spot
welding;Welding
Gas tungsten arc welding (GTAW) 309
Gas welding
definitions 2567
development 2489
oxy-acetylene equipment 250
acetylene supply 2501
assembly 256
automatic flashback arrester 254
cylinder key 255
cylinder trolley 255
gas hose 2545
goggles 255
hose check valve 255
oxygen supply 2512
regulators 2534
torches 2523
systems 249
Gases
acetylene 268
argon 2667
argoshield 268
carbon dioxide 268
hydrogen 268
nitrogen 266
oxygen 266
propane 2678
safety measures
acetylene cylinders 268
general storage procedures 268
oxygen cylinders 2689
632 Index
Gases (Continued)
usage/handling of cylinders
fire 269
leaks 269
ventilation/oxygen-enriched areas 2701
Genesis electronic measuring system 4335
Glass-Weld Pro-Vac system 4712
Glasss Guide Services (Glassmatrix II) 4948
Glazing systems
direct windscreen removal/replacement 4678
hot knife 46870
piano wire 468
pneumatic/electric cutter 468
indirect windscreen removal/replacement 4657
Globaljig universal bracket system 4213
Grinder 3634
Guillotine 1701
Hacksaws 1034
Hammering 358
direct 35960
indirect (off dolly block) 3601
removing low spots 362
roughing out damage 3589
spring 3612
Hammers
curved pein and finishing 87
dinging 86
engineers ball-pein 99
fender bumping 87
file hammer/beating file 87
hollowing/blocking 99
light bumping 856
mallets 878
pick and finishing 867
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 16970
Hand snips 912, 1023
Hand tools 85
body files 901
body spoons 8990
dollies 889
fabrication of sheet metal 98
hammers 858
hand snips 912
specialist panel beating tools 928
Hard solders
aluminium brazing 243, 245
brazing 2402
bronze welding 2457
silver soldering 2423
Hardwood blocks 100
Health and safety 59, 368
electrical hazards 75
check list 75
voltages 75
fire precautions 6570
general 725
legislation 756, 51617
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 767
identifying/removing hazards 778
injuries reported immediately 7980
isolating machines/equipment 82
minimizing risk 78
people come first 80
professional emergency services 801
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 789
use of appropriate safety clothing/
equipment 834
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personal
ear protection 645
eyes and face protection 61
foot protection 61
hand protection 59
head protection 61
protective clothing 5960
Index 633
respiratory protection 634
skin care 59
signs 701
Health and Safety at Work Act (HSWA) 76
Heat treatment
aluminium alloys 1667
carbon steel 1645
case hardening 166
hardening 165
normalizing 165
tempering 1656
work hardening/annealing 1634
High-carbon steel 128
High-strength low-alloy (HSLA) steel 125, 131
High-strength steel (HSS) 125, 1301
cost 131
properties 131
repair 1312
spotting 132
High-tensile steel 130
History 12, 8
highlights 810
Hot shrinking 364
aluminium 366
equipment 366
process 3656
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 41213
Joining methods
adhesives 22333
bifurcated, tubular, semitubular rivets 199
blind rivets 2008
development 197
fastening devices 21823
screws and bolts 21118
solid rivets 1979
structural fasteners 20810
Junction 256
Korek system 40810
Kroll Autorobot system
Autorobot L 436
III Super 437
XLS II 4367
Lap joints 256
Latex foam 142
Legislation
Control of Substances Hazardous to Health
(COSHH) (1988) 51721
Environment Protection Act (1990) 5223
health and safety 51617
Management of Health and Safety at Work
Regulations (1992) 5234
Manual Handling Operations (1992) 525
paint storage, fire precautions, fire fighting 516
Personal Protective Equipment (PPE) at
Work (1992) 5245
Provision and use of Work Equipment
Regulations (1992) 524
risk assessment 5268
statutory 516
Workplace (Health, Safety and Welfare) (1992)
5256
Light-gauge steel 3067
Lotus Cars Ltd 5467, 5602
Low-carbon steel 1245
Low spot removal 362
Lungs, see Respiratory protection
Major accident damage 405
alignment of modern integral body 43849
concealed 405
costing/estimating
computer estimating 486
costing 483
estimating 4836
Glassmatrix II system 4948
insurance procedure 486, 491
motor insurance (Thatcham) 4912
repair/replacement 4823
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 4067
Blackhawk mobile system PB30 428
car bench 41921
Car-O-Liner systems 42831
634 Index
Major accident damage (Continued)
Celette UK 5000 pulling system 412, 41319
Chief E-Z Liner II system 4323
choice of systems 4378
Dataliner 4247
Dozer equipment 4078
Genesis electronic measuring system 4335
Globaljig universal bracket system 4213
jig brackets 41213
Korek body/frame straightening system
40810
Kroll Autorobot multifunctional system
4367
Mitek anchor pot collision system 41012
Universal Bench 4234
rear-end 4056
repair techniques 44952
door hanging 4645
extensively damaged panels 463
heat barrier material 4634
monocoque bodies by pulling 4525
motor vehicle glazing systems 46570
partial panel replacement 4613
plastic repair 4778
plastics welding 4727
replacement of panels 457, 45961
underbody damage of monocoque vehicles
4556
valeting 47882
water leak detection 4701
wheel alignment (steering geometry) 4567
windscreen repair 4712
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) 5234
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 2978
choice of system 297
electrical terms 295
electrodes used (BS coding) 2989
additional coding 299
coding example 299300
dimensions/tolerances 300
identification 3001
strength, toughness, covering (STC) 299
equipment
AC transformers 2967
DC generator 2956
essential factors
correct arc length 302
correct choice of electrode 302
correct current 3023
correct speed of travel 302
design of joint 3046
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 2945
safety precautions 3078
technique
aluminium and alloys 307
light-gauge steel 3067
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 1845
instruments
bevel gauge 188
bevel protractors 188
calipers 18990
centre square 1889
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 1912
scribers 1856
straight edges 186
Index 635
trammels (beam compasses) 189
try square (engineers square) 187
precision instruments
engineers level 194
marking-off table 1923
micrometer 1956
surface gauge/scribing block 1934
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 1678
U-channels/box sections 168
Metal movement 180
Metal shaping 3423
hollowing 3434
planishing 34850
puckering 343
raising 343, 3445
split-and-weld system 348
wheeling 343, 3458
Metal shears 110, 112
Metals
properties
compressibility 163
ductility 1612
elasticity 163
fatigue 163
hardness 162
malleability 1601
tenacity 162
toughness 1623
weldability 163
Micro-alloyed steel 125, 128
MIG/MAG welding 309, 31920
body repair work 3323
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 33940
equipment 3217
feed unit 3256
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 3289
power unit 3212
control panel 3223
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 32930
quality control (BS EN ISO 90012000) 340
spot/plug welding 3201
stress/distortion 3358
residual 3357
techniques 3279
testing and distortion 33940
vehicle body construction 3312
visible examination 339
welding torch 325
welding wire 3267
Mild steel 263, 306
Mini sheet metal cutter 104
Minor accident damage
aluminium panels 3908
body electrical/electronic systems
398403
body jack 37280
body panels 38090
body soldering 3678
chemically hardening fillers 36872
cold shrinking 3667
636 Index
Minor accident damage (Continued)
edge stiffening of sheet metal 3536
fabrication of hand-made panels 3503
filling 3623
hammering techniques 35862
hot shrinking 3646
panel beating by hand 342
rectification techniques 3568
safety points 368
sanding/disc grinding 3634
shaping metal by hand 34250
Mitek system 41012
Monodex cutters 103
Motor Insurance Repair Research Centre (Thatcham)
4912
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 5679
Mudguards 2
Nibbler 112
Nibbling machines 170
Non-corrosive fluxes 2378
olive oil 238
resin and linseed oil 238
tallow and palm oil 238
Nuts 216
aerotight 21617
captive 21820, 2213
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 2506
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 512
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 956
impact driver 94
inter-grip welding clamp 967
panel puller 923
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)
5245
Plasma arc cutting
methods 274
contact 274
distance 274
process advantages 2745
process/equipment 2712
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 2734
Plastic fillers 368, 3702
Index 637
Plastics
abbreviations 153
amorphous/crystalline 150
applications 150, 152
development 148
future 151, 153
identification markings 154
manufacturing processes 1545
mechanical properties 149
painting 156
polymerization 148
reinforcement 154
repair 1556
safety 155
thermoplastics/thermosetting 148, 150
types 1534
Plastics welding 4724
defects 477
charred weld 477
poor penetration/bonding 477
uneven bead width 477
warping 477
equipment 4745
identification 474
thermoplastic 474
thermosetting 474
repair method 4756
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 10910
Pre-impregnated material (pre-preg) 5589
core materials 559
curing 559
foam 559
heat 560
honeycomb 559
Precision instruments, marking out, see Marking out
Production
full-size models 213
scale models 21
Prototypes 24
testing 247
Provision and use of Work Equipment
Regulations (1992) 524
Punches
hole 95
wing 95
Quality management (BS EN ISO 90012000)
benefits 529
bodyshop action plan 529
consultants 530
implementation/assessment 530
requirements 5289
Ratchet wrench 117
Rear quarter panel/tonneau 49
Rear wheel arch 49
Refinishing 602
acrylic lacquer 605
complete respray from pretreated bare metal
6056
complete respray over existing finish
local repair 606
cellulose synthetic
bare metal 6034
local repair 6045
over existing finish 604
coach finish 6023
low-bake enamels 608
advantages 612
developments 612
equipment 6089
finishing 61112
preparation for stoving 609
preparatory work 609
spraying 609
stoving 61011
metallic finishes 6068
quick air drying synthetics 608
short-wave infrared paint drying 61213
two-pack paint system 61314
water-based paint 614
Refinishing materials
abrasive papers 5801
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 57980
638 Index
Refinishing materials (Continued)
sealers
bleed-inhibiting 580
isolating 580
standard 580
solvents 5812
Reinforced composite materials
applications 5389
basic principles 5334
body production in plastic (Lotus) 5602
common faults in moulded laminates 56771
designing for strength 547, 54950
composite theory 5501
fabric types and constructions 5516
pre-impregnated material (pre-preg) 55660
reinforcing fibres 551
resin 551
development 5323
manufacture 5346
moulding techniques
contact 5425
hot press 546
production processes 5467
spray-up technique 5456
repair 562
accident damage assessment 5623
accident repair 563
blind panel 566
body scratch or gash 5656
damaged wing 5635
important points 5667
replacing part components 566
resins 53940
adhesives used with GRP 542
catalysts and accelerators 540
core materials 542
fillers and pigments 541
formers 542
pre-accelerated 5401
releasing agents 5412
safety precautions 572
fire hazards 573
operating 572
spillage and disposal 5723
storage 572
workshop conditions 572
types
carbon fibre 539
chopped strand mat 5367
chopped strands 537
needle mat 537
rovings 537
staple fibres 537
woven fabrics 536
Repainting preparation 600
abrasive paper 601
paint remover 6001
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 3968
oxidation 394
riveting 394
temperature measurement 394, 396
body panels
major accident 381
minor accident 3801, 382
rust damage 3812
bonnets 3867
door panels 383
electrical/electronic systems 398
SAE J1930 399402
safety check 4023
terminology 3989
pulling out double skin panel damage
reinforced composite materials 5627
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)
756
Resistance welding 2778
ARO Spotrite Pulsa system 28790
body repair work 282
butt 2812
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 2867
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 2801
spot welding 27980
spot welding of high-strength steels 282, 284
electrodes 2856
heat application 285
heat balance 285
quality 2845
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 634
constant-flow air line breathing apparatus 64
dust masks 63
power respirators 64
Risk assessment 5268
Rivet sets 102
Rivets
bifurcated, tubular, semitubular 199
blind 2008
solid 1978
Rolling machines
bending 173
cone 174
pinch 1734
pyramid 174
safety measures 175
Roof panel 47, 49
Rubber
natural 141
synthetic 1412
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 61820
spray nozzles
flexible lance 617
hook nozzle 617
rigid lance 61617
rules foe selection 617
straight nozzle 617
Safety 1619, 21
primary/active 17
secondary/passive 17
see also Health and safety
Safety glass 156
adhesive systems 158
crossbreeds 1578
laminated 157, 158
standards 157
toughened 157
vinyl interlayer 157
Sandbags 100
Sanding machines 598600
belt 115
disc 11415, 364
dual-action 115
geared orbital sander/polisher 116
oscillating 11617
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) 1089
Torx 109
Screws
coach screws 215
machine 216
metal (self-tapping) 211, 21314
screw nails 21415
steel hammer drive screws 214
wood 211
Sealers 142, 144, 145
Semi-crystalline plastics 150
Shearing theory 169
Sheet metal bench stakes 1002
anvil 100
ball 102
beck iron 102
funnel 100
grooving 100
half-moon 102
hatchet 102
640 Index
Sheet metal bench stakes (Continued)
horse stake with heads 102
panel head 102
pipe 100
round-bottom 102
side 102
tinmans 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 2423, 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 527
Society of Automotive Engineers (SAE) 399
Socket sets 1078
Soft solders 236
fluxes 2378
process 2389
apply soldering iron 23940
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 2407
soft 23640
Solid rivets 1979
dimensions 198
holes 1978
types of joint 1989
Sound deadening 1446
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 5867
high-volume low-pressure
(HVLP) 587
maintenance and cleaning
gravity-feed gun 590
lubrication 592
pressure-feed gun 5902
suction-feed gun 590
mix methods
external 586
internal 586
motion study 592
curved surfaces 593
external corners 593
flat surfaces 5923
internal corners 594
sequence 5945
paint supply methods
gravity-feed 5845
pressure-feed 5856
suction-feed 584
spraying defects 595
air leakage 597
compressing overheating 598
faulty packing 597
faulty patterns 5967
fluttering 5956
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
6245
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 5823
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 6201
matt finish 576
shrinkage 576
sinkage 5767
tacking off 577
terms, air delivery 576
types
blacking 578
cellulose synthetic 577
low-bake finishes 579
oil 577
stoving 5778
synthetic 577
two-pack 5789
viscosity 577
Stainless steel 1323, 264, 307
austenitic 133
austenitic/ferritic duplex 133
ferritic 133
Steel
annealing 1223
casting 122
finishing 123
material grades, chemical compositions,
types 1267
pickling, cold rolling steel 122
specifications 1234
temper rolling 123
Steering 2
Structural fasteners 208
Avdelok system 209
avtainer system 210
monobolt system 210
threaded inserts 20910
Swaging machines 1768
Swaging tool 105
T-joints 256
Tailgate 50
Testing
engine 23
impacts 2930
prototypes 247
Thatcham 4912
Thermal insulating 1446
Thermoplastics 148, 474
engineering 148, 150
general-purpose 148
Thermosetting materials 148, 150
Throat 257
TIG welding 309
application of welding 319
equipment used 31516
filler metals 317
gas supply 317
power unit 316
TIG electrodes 31718
welding torch 31617
modes of operation 313
principles of operation 31213
spot welding 31415
welding techniques 31819
Toe 256
Toolchests 109
Transformation induced plasticity (TRIP) 131
Trims 51
Ultra Light Steel Auto Body (ULSB) 131
Ultra Light Steel BodyAdvanced Vehicle Concepts
(ULSBACV) 131
Underbody 46, 43941, 442, 4556, 61820
Undercut 2567
Undersealing materials 1446
Universal Bench systems 423
bracketless 4234
642 Index
Valeting 478
cleaning process 479
checklist 482
dry bay 4812
wet bay 47980
premises, equipment, chemicals 4789
Vehicle classification 11
Vehicle identification numbers (VIN) 52
Vehicle type approval 527
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 2634
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 25960
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 1756
Wheels 2
Windscreens 2
repairs
direct removal/replacement 4678
Glass-Weld Pro-Vac 4712
indirect removal/replacement 46870
Wings 49
Workplace (Health, Safety and Welfare)
Regulations (1992) 5256
Wrenches 106
adjustable 107
Wrought light aluminium alloys (BS specifications
14701475)
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
