9780766813984

I-Car Professional Automotive Collision Repair

by
  • ISBN13:

    9780766813984

  • ISBN10:

    0766813983

  • Edition: 2nd
  • Format: Hardcover
  • Copyright: 2000-12-18
  • Publisher: Cengage Learning

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  • The New copy of this book will include any supplemental materials advertised. Please check the title of the book to determine if it should include any access cards, study guides, lab manuals, CDs, etc.
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Summary

Learn all the latest methods to repair and refinish damaged automobiles. Written in plain English and lavishly illustrated, this book is great for hobbyists through individuals interested in entering the collision repair field. Comprehensive coverage includes safety, tools, repair of body damage, structural repair, and refinishing and painting and collision-related mechanical repairs. Includes a full-color introduction to refinishing including the latest gravity-fed high-efficiency spray guns. The latest computerized mixing scales, putties, sanders and polishing pads as to the panoply of new technology this author has brought to this book.

Table of Contents

Preface ix
About the Book ix
Features of the Text xi
Supplements xv
About I-CAR xvi
Acknowledgments xvi
SECTION 1 FUNDAMENTALS
Industry Overview and Careers
3(18)
History Note
5(1)
Collision Repair Technician
5(1)
Other Personnel
5(1)
The Professional
5(1)
What is Collision Repair?
6(1)
What is a Collision?
6(1)
Vehicle Construction Basics
6(3)
Shop Operations
9(8)
Collision Repair Facilities
17(1)
Summary
17(1)
Technical Terms
18(1)
Review Questions
18(1)
ASE-Style Review Questions
19(1)
Activities
20(1)
Safety and Certification
21(20)
What Causes Accidents?
22(1)
Types of Accidents
22(1)
Textbook Safety
22(1)
Overall Shop Safety
22(1)
Shop Layout and Safety
23(2)
In Case of an Emergency
25(1)
Work Area Safety
25(1)
Fire Safety
25(2)
Avoiding Falls
27(1)
Avoiding Electrocution
28(1)
Avoiding Asphyxiation
28(1)
Avoiding Eye Injuries
28(1)
Avoiding Chemical Burns
28(2)
Personal Safety
30(1)
Tool and Machine Safety
31(2)
Paint Shop Safety
33(1)
Respirators
33(2)
Dustless Sanding Systems
35(1)
Air Bag Safety
35(1)
Manufacturer's Warnings
35(1)
Right-to-Know Laws
36(1)
Employer Responsibilities
36(1)
Waste Disposal
36(1)
Liability
36(1)
Technician Liability
36(1)
ASE Certification
37(1)
I-CAR
37(1)
Don't Be Foolish!
38(1)
Summary
38(1)
Technical Terms
38(1)
Review Questions
39(1)
ASE-Style Review Questions
40(1)
Activities
40(1)
Vehicle Construction
41(17)
Crash Testing
42(1)
Vehicle Classifications
42(1)
Vehicle Construction
42(4)
Joining Parts
46(1)
Major Body Sections
47(1)
Panel and Assembly Nomenclature
48(1)
Front Section Parts
49(1)
Center Section Parts
49(2)
Rear Section Parts
51(1)
Gaskets and Seals
51(1)
Anticorrosion Materials
51(1)
Sound-Deadening Materials
51(1)
Engine Locations, Drive Lines
51(2)
Vehicle Sizes
53(1)
Roof Designs
54(1)
Vans and Trucks
55(1)
Summary
55(1)
Technical Terms
55(1)
Review Questions
56(1)
ASE-Style Review Questions
56(1)
Activities
57(1)
Hand Tools
58(21)
Purchase Quality Tools
59(1)
Tool Storage
59(1)
General Duty Hammers
59(1)
Body Hammers
60(1)
Dollies and Spoons
60(1)
Holding Tools
60(1)
Punches and Chisels
60(2)
Wrenches
62(1)
Wrench Types
62(3)
Pry Bars
65(1)
Screwdrivers
65(1)
Pliers
66(1)
Sheet Metal Tools
66(1)
Files
66(3)
Saws
69(1)
Cleaning Tools
70(1)
Creepers, Covers
70(1)
Hydrometers
70(1)
Fluid Handling Tools
70(1)
Tire Tools
71(1)
Pullers, Picks
71(1)
Miscellaneous Collision Repair Tools
72(3)
Summary
75(1)
Technical Terms
76(1)
Review Questions
76(1)
ASE-Style Review Questions
77(1)
Activities
78(1)
Power Tools and Equipment
79(25)
Air Supply System
80(1)
Air Compressor
80(1)
Air Lines
81(1)
Air Pressure Regulator and Filter
81(1)
Air Tools
81(4)
Grinders
85(1)
Polishers
86(1)
Pneumatic Tool Maintenance
86(1)
Blasters
86(1)
Spray Guns
87(5)
Spray Booths
92(1)
Paint Drying Equipment
93(1)
Measuring Systems
93(1)
Straightening Systems
93(1)
Lifts
94(1)
Electric Tools
95(1)
Battery Charger
96(1)
Multimeter
96(1)
Multimeter
96(1)
Scan Tools
97(1)
Engine Analyzer
98(1)
Personal Computer
98(1)
Soldering Gun
98(1)
Plastic Welder
98(1)
Air Conditioning Tools
98(1)
Other Equipment
99(1)
Summary
100(1)
Technical Terms
101(1)
Review Questions
102(1)
ASE-Style Review Questions
102(1)
Activities
103(1)
Basic Measurement and Service Information
104(20)
SAE and Metric Systems
105(1)
Conversion Charts
106(1)
Linear Measurements
106(1)
Scales
106(2)
Dividers and Calipers
108(1)
Micrometers
109(1)
Dial Indicators
109(1)
Feeler Gauges
110(2)
Pressure and Flow Measurements
112(1)
Angle Measurements
112(1)
Temperature Measurements
112(1)
Paint-Related Measurements
113(1)
Paint Mixing Sticks
114(1)
Viscosity Cup Measurement
114(1)
Paint (Material) Thickness Measurement
114(2)
Vehicle Identification Number (VIN)
116(1)
Collision Repair Publications
116(1)
Computerized Service Information
117(4)
Color Matching Manuals
121(1)
Summary
121(1)
Technical Terms
121(1)
Review Questions
122(1)
ASE-Style Review Questions
122(1)
Activities
123(1)
Fasteners
124(14)
Bolts
125(3)
Nuts
128(1)
Thread Repair
128(1)
Washers
129(1)
Screws
130(1)
Nonthreaded Fasteners
130(3)
Replacing Fasteners
133(1)
Hose Clamps
133(1)
Adhesives
133(3)
Summary
136(1)
Technical Terms
136(1)
Review Questions
136(1)
ASE-Style Review Questions
136(1)
Activities
137(1)
Collision Repair Hardware and Materials
138(19)
Refinishing Materials
139(1)
Undercoats and Topcoats
139(1)
Paint Types
139(1)
Original Equipment Manufacturer (OEM) Finishes
140(1)
Contents of Paint
140(1)
Drying and Curing
141(1)
Primers and Sealers
142(1)
Sealers
143(1)
Primer-Surfacers
143(1)
Use a Complete System!
144(1)
Other Paint Materials
144(2)
Body Fillers
146(1)
Glazing Putty/Finishing Fillers
147(1)
Masking Materials
147(1)
Abrasives
148(1)
Grinding Discs
149(1)
Sandpapers
150(1)
Scuff Pads
150(1)
Compounds
151(1)
Adhesives
151(1)
Epoxies
152(1)
Sealers
153(1)
Hazardous Materials
153(1)
Waste Disposal and Recycling
154(1)
Summary
154(1)
Technical Terms
154(1)
Review Questions
155(1)
ASE-Style Review Questions
156(1)
Activities
156(1)
Welding, Heating, and Cutting
157(32)
What is Welding?
158(1)
Weld Terminology
158(1)
Welding Categories
158(2)
Metal Inert Gas (MIG) Welding
160(7)
Welding Positions
167(2)
Welding Safety
169(1)
Welding Surface Preparation
170(1)
Holding Parts
170(1)
Weld-Through Primer
171(1)
Using the MIG Welder
171(1)
MIG Burnback
171(1)
Wire Speed
172(1)
Shielding Gas Flow Rate
172(1)
Heat Buildup Prevention
172(1)
Clean After Welding
172(1)
Resistance Spot Welding
172(6)
Weld Problems
178(1)
Welding Aluminum
178(3)
Oxyacetylene Welding
181(2)
Plasma Arc Cutting
183(2)
Summary
185(1)
Technical Terms
186(1)
Review Questions
186(1)
ASE-Style Review Questions
187(1)
Activities
187(2)
SECTION 2 MINOR REPAIRS
Straightening Fundamentals
189(28)
Sheet Metal
190(1)
Steel Strength
190(1)
Physical Structure of Steel
191(1)
Effect of Impact Forces
191(1)
Work Hardening
191(1)
Kinds of Damage
191(1)
Using Body Hammers
191(1)
Straightening with Dollies
192(1)
Hammer-on-Dolly
192(2)
Hammer-off-Dolly
194(1)
Straightening with Spoons
195(1)
Straightening with Picks
196(1)
Pulling Damaged Areas
197(1)
Shrinking Metal
198(1)
Identifying Stretched Metal
199(1)
Filing the Repair Area
200(1)
Working Aluminum
200(1)
Using Body Filler
200(2)
Preparing Surface for Filler
202(12)
Summary
214(1)
Technical Terms
214(1)
Review Questions
215(1)
ASE-Style Review Questions
215(1)
Activities
216(1)
Plastic and Composite Repair
217(25)
Types of Auto Plastics
218(1)
Plastics Safety
218(1)
Plastic Identification
219(3)
Plastic Part Removal
222(2)
Principles of Plastic Welding
224(1)
Hot-Air Plastic Welding
224(2)
Airless Plastic Welding
226(1)
Plastic Welding Methods
226(1)
Hot-Air Plastic Welding Procedure
226(1)
Plastic Tack Welding
227(1)
Welding a Plastic V-Groove
227(1)
Plastic Speed Welding
228(1)
Airless Melt-Flow Plastic Welding
229(1)
Plastic Stitch-Tamp Welding
229(1)
Single-Sided Plastic Welds
229(1)
Two-Sided Plastic Welds
229(1)
Repairing Vinyl Dents
230(1)
Welding Vinyl-Foam Cuts
230(1)
Heat Reshaping Plastic Parts
231(1)
Plastic Bumper Tab Replacement
231(1)
Plastic Adhesive Repair Systems
231(1)
Use the Correct Adhesive!
232(1)
Two-Part Plastic Adhesive Repairs
232(1)
Two-Part Adhesive Dash Repair
233(1)
Reinforced Plastic Repairs
233(2)
Reinforced Plastic Adhesives
235(1)
Reinforced Plastic Fillers and Glass Cloth
235(1)
Reinforced Plastic, Single-Sided Repairs
236(1)
Two-Sided Repairs of Reinforced Plastic
236(2)
Using Molded Cores
238(1)
Repairing RRIM
238(1)
Spraying Vinyl Paints
239(1)
Summary
239(1)
Technical Terms
239(1)
Review Questions
240(1)
ASE-Style Review Questions
240(1)
Activities
241(1)
Replacing Hoods, Bumpers, Fenders, Grilles, and Lids
242(18)
How are Parts Fastened?
243(1)
Refer to Estimate
243(1)
Where to Start
244(1)
Hood Removal and Replacement
245(5)
Bumper Removal, Replacement, and Adjustment
250(1)
Fender Removal, Replacement, and Adjustment
250(2)
Grille Removal and Replacement
252(2)
Deck Lid Removal, Replacement, and Adjustment
254(1)
Panel Alignment
254(1)
Truck Bed Removal and Replacement
255(2)
Installing Sound-Deadening Pads
257(1)
Summary
257(1)
Technical Terms
258(1)
Review Questions
258(1)
ASE-Style Review Questions
258(1)
Activities
259(1)
Servicing Doors, Glass, and Leaks
260(23)
Doors
261(1)
Door Construction
261(2)
Door Adjustments
263(8)
Glass
271(6)
Air and Water Leaks
277(1)
Rearview Mirror Service
278(1)
More Information
278(1)
Summary
278(1)
Technical Terms
279(1)
Review Questions
279(1)
ASE-Style Review Questions
279(1)
Activities
280(3)
SECTION 3 PREPAINTING PREPARATION
Vehicle Surface Preparation
283(20)
Vehicle Cleaning
284(1)
Surface Evaluation
285(1)
Chemical Stripping
286(2)
Blasting Paint
288(1)
Removing Paint
288(1)
Bare Metal Treatment
288(1)
Preparing Metal Replacement Parts
289(1)
Sanding
289(3)
Featheredging
292(1)
Undercoat Systems
292(2)
Using Spot Putty
294(1)
Using a Guide Coat
294(1)
Masking
294(6)
Summary
300(1)
Technical Terms
300(1)
Review Questions
301(1)
ASE-Style Review Questions
301(1)
Activities
302(1)
Shop and Equipment Preparation
303(17)
Painting Environment
304(1)
Preparing Spray Booth
304(4)
Mixing and Storage Area Prep
308(1)
Preparing Spray Equipment
308(2)
Mixing Paint and Solvent
310(3)
Viscosity
313(1)
Paint Temperature
314(1)
Captive Spray Gun System
315(3)
Summary
318(1)
Technical Terms
318(1)
Review Questions
318(1)
ASE-Style Review Questions
319(1)
Activities
319(1)
SECTION 4 REFINISHING
Painting and Refinishing Fundamentals
320(25)
Preparation Review
322(2)
Review of Topcoats
324(2)
Determining Type of Finish
326(1)
Spray Gun Application Stroke
326(5)
Paint/Material Thickness Measurement
331(1)
Gun Handling Problems
332(1)
Types of Spray Coats
332(1)
Paint Blending
332(1)
Refinishing Methods
333(1)
Spot Repairs
333(1)
Panel Repairs
334(1)
Overall Refinishing
335(1)
Applying Basecoat-Clearcoat
336(1)
Applying Tri-Coat Finishes
337(1)
Refinishing Rules
337(1)
Removal of Masking Materials
338(1)
Finishing Rigid Exterior Plastic Parts
338(1)
Finishing Polypropylene Parts
339(1)
Finishing Urethane Bumpers
339(1)
Cleaning the Spray Gun
339(1)
Spray Gun Cleaning Steps
340(2)
VOC Tracking
342(1)
Summary
342(1)
Technical Terms
342(1)
Review Questions
342(1)
ASE-Style Review Questions
343(1)
Activities
344(1)
Color Matching
345(24)
Color Theory
346(1)
Lighting
346(2)
Color Blindness
348(1)
Dimensions of Color
348(2)
Metamerism
350(1)
Plotting Color
350(1)
Color Matching
351(2)
Paint Formulas
353(1)
Spectrophotometer
354(1)
Computerized Color Matching Systems
354(1)
Color Variance Programs
354(1)
Spray Methods Affect Color
355(1)
Matching Solid Colors
355(1)
Matching Metallic Finishes
355(2)
Matching Multi-Stage Finishes
357(1)
Zone Concept
358(1)
Color Flop
358(1)
Checking Color Match
358(2)
Blending Clearcoats
360(1)
Fluorine Clearcoat Repairs
360(1)
Tri-Coat Spot Repair
360(1)
Tri-Coat Panel Repair
360(2)
Blending Mica Coats
362(1)
Matching Mica Colors
362(1)
Why a Color Mismatch?
363(1)
Tinting
363(2)
Summary
365(1)
Technical Terms
365(2)
Review Questions
367(1)
ASE-Style Review Questions
367(1)
Activities
368(1)
Paint/Refinish Problems and Final Detailing
369(18)
Surface Imperfections
370(1)
Surface Finish Measurements
370(1)
Paint Problems
370(7)
Final Detailing
377(6)
Get Ready
383(1)
Caring for New Finish
383(1)
Summary
384(1)
Technical Terms
384(1)
Review Questions
385(1)
ASE-Style Review Questions
385(1)
Activities
386(1)
Decals, Custom Painting, and Trim
387(12)
Overlays and Tape Stripes
388(3)
Painted Pinstripes
391(1)
Custom Painting
392(1)
Moldings and Trim
393(2)
Summary
395(1)
Technical Terms
395(1)
Review Questions
396(1)
ASE-Style Review Questions
396(1)
Activities
397(2)
SECTION 5 MAJOR REPAIRS
Measuring Vehicle Damage
399(32)
Why is Measurement Important?
400(1)
Damage Diagnosis
400(1)
Safety
401(1)
Impact Effects
401(1)
Analyzing Collision Forces
402(1)
Types of Frame Damage
403(2)
Unibody Vehicle Damage
405(2)
Dimensional References
407(1)
Vehicle Measuring Basics
408(1)
Types of Measuring Equipment
408(19)
More Information
427(1)
Summary
428(1)
Technical Terms
428(1)
Review Questions
429(1)
ASE-Style Review Questions
429(1)
Activities
430(1)
Straightening Full-Frame and Unibody Vehicles
431(32)
Alignment Basics
432(2)
Straightening Equipment
434(6)
Measure As You Pull!
440(1)
Part Removal
440(2)
Planning the Straightening
442(1)
Straightening Safety
443(1)
Straightening Basics
443(1)
Anchoring Procedures
444(1)
Wheel Clamps
445(1)
Attaching Pulling Chains
445(4)
Executing a Planned Straightening Sequence
449(1)
Straightening Directions
449(3)
Overpulling
452(1)
Aligning Front End Damage
453(1)
Rear Damage Repairs
454(1)
Straightening Side Damage
455(1)
Straightening Sag
455(1)
Straightening Diamond Damage
456(1)
Stress Relieving
457(1)
Stress Concentrators
458(1)
Final Straightening/Alignment Checks
458(1)
Summary
459(1)
Technical Terms
459(1)
Review Questions
459(1)
ASE-Style Review Questions
459(1)
Activities
460(3)
SECTION 6 OTHER OPERATIONS
Replacing Structural Parts and Corrosion Protection
463(31)
Repair or Replace Guidelines
464(1)
Types of Structural Replacements
464(1)
Determining Spot Weld Locations
465(1)
Separating Spot Welds
465(1)
Separating Continuous Welds
466(1)
Preparing Vehicle for New Panel
466(1)
Preparing Replacement Panel/Part
467(1)
Positioning New Panels
467(1)
Welding New Panels/Parts
468(1)
Sectioning
468(17)
Corrosion
485(6)
Summary
491(1)
Technical Terms
492(1)
Review Questions
492(1)
ASE-Style Review Questions
492(1)
Activities
493(1)
Interior Repairs
494(10)
Seat Service
495(1)
Carpeting Service
496(2)
Headliner Service
498(1)
Instrument Panel Service
499(1)
Instrument Cluster Service
499(3)
Summary
502(1)
Technical Terms
502(1)
Review Questions
502(1)
ASE-Style Review Questions
502(1)
Activities
503(1)
Mechanical Repairs
504(23)
Powertrain
505(1)
Engine Support Systems
506(3)
Drivetrain
509(4)
Steering Systems
513(3)
Suspension Systems
516(2)
Air Conditioning Systems
518(4)
Emission Control Systems
522(2)
Summary
524(1)
Technical Terms
524(1)
Review Questions
525(1)
ASE-Style Review Questions
525(1)
Activities
526(1)
Wheel Alignment
527(19)
Wheel Alignment Basics
528(7)
Prealignment Checks
535(2)
Diagnostic Checks
537(1)
Wheel Alignment Procedures
538(2)
Alignment Equipment Variations
540(1)
Road Test After Alignment
540(1)
Summary
540(2)
Technical Terms
542(1)
Review Questions
542(3)
ASE-Style Review Questions
545(1)
Activities
545(1)
Electrical Repairs
546(32)
Electrical Terminology
547(1)
Diagnostic Equipment
548(2)
Wiring Diagrams
550(1)
Electric Components
551(5)
Circuit Protection Devices
556(1)
Fuses
557(1)
Fuse Links
557(2)
Circuit Breakers
559(1)
Electrical-Electronic Systems
560(2)
Electrical Problems
562(1)
Batteries
563(3)
Lighting and Other Electric Circuits
566(1)
Repairing Wiring and Connections
566(1)
Solder Repair
566(2)
Electrical Connector Service
568(1)
Computer Systems
569(2)
Scanning Computer Problems
571(3)
Protecting Electronic Systems
574(1)
Summary
575(1)
Technical Terms
575(1)
Review Questions
576(1)
ASE-Style Review Questions
576(1)
Activities
577(1)
Restraint System Repairs
578(15)
Active and Passive Restraints
579(1)
Seat Belt Systems
579(3)
Child Restraint Systems and Air Bag Safety
582(1)
Air Bag Systems
582(7)
Summary
589(1)
Technical Terms
589(1)
Review Questions
589(1)
ASE-Style Review Questions
589(1)
Activities
590(3)
SECTION 7 ESTIMATING AND ENTREPRENEURSHIP
Estimating Repair Costs
593(23)
Damage Analysis
594(1)
Direct and Indirect Damage
594(1)
Vehicle Inspection
595(3)
Interior Inspection
598(1)
Damage Quick Checks
599(1)
Dimension Manuals
600(1)
Collision Estimating Guides
600(2)
Damage Report Terminology
602(1)
Part Costs
602(1)
Writing Estimates
603(3)
Estimating Sequence
606(1)
Flat Rate Operations
606(1)
Labor Costs
606(1)
Refinishing Time
607(1)
Total Labor Costs
608(1)
Totaling the Estimate
608(1)
Computerized Estimating
608(2)
Front Clips
610(2)
Sectioning
612(1)
Total Loss
613(1)
Summary
613(1)
Technical Terms
613(1)
Review Questions
613(1)
ASE-Style Review Questions
614(1)
Activities
615(1)
Enterpreneurship and Job Success
616(5)
Collision Repair Technician
617(1)
Related Professions
617(1)
Entrepreneurship
617(1)
Cooperative Training Programs
618(1)
Keep Learning!
618(1)
Use a Systematic Approach
618(1)
Work Traits
618(1)
Summary
619(1)
Technical Terms
619(1)
Review Questions
619(1)
ASE-Style Review Questions
619(1)
Activities
620(1)
Glossary 621(26)
Appendix A Abbreviations Used by Collision Repair Technicians 647(3)
Appendix B Measurement Equivalents 650(3)
Appendix C Tap and Drill Bit Data 653(3)
Appendix D Reference Tables 656(1)
Appendix E Torque Values 657(4)
Index 661

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