I-Car Professional Automotive Collision Repair

by Duffy, James E.

• ISBN13: 9780766813984
• ISBN10: 0766813983
• Edition: 2nd
• Format: Hardcover
• Copyright: 2000-12-18
• Publisher: Cengage Learning

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