Module 12: Estimating Repair Costs (Optional)

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Module 12: Estimating Repair Costs (Optional)

Suggested time: 10-20 hours Level: Advanced

Module Overview

Students will learn the procedures for identifying necessary repairs. They will use flat rate manuals for labour costs and parts manuals to price parts. Additional factors such as towing, shop supplies, applicable taxes, new or used parts and parts depreciation will be explained and included in estimates.

Foundational Objectives

To evaluate damage to motor vehicles in order to determine corrective work procedures.
To estimate technical measurements and time for repair.
To recommend procedures and select appropriate products for use in autobody repair.

Common Essential Learnings Foundational Objectives

To recognize and practise safety in all situations encountered. (COM)
To explore numeracy as it applies to the autobody industry. (NUM)

Note: Other CELs may be emphasized.

Learning Objectives	Notes
12.1 To identify the role of insurance in the industry.	Discuss terms such as: Insurance Liability Waiver write-off premium deductible package policy, etc.
12.2 To estimate damage repair costs. (NUM, TL)	Record preliminary information such as: the name of the owner insurance coverage available who will pay the bill plate number mileage make model year serial number body style date of the estimate The written estimate should include: a detailed description of all labour operations that must be performed; complete list of parts and materials needed for the repair; and a total price including labour, parts, materials and taxes. Before any work is done, the vehicle owner, the insurance company and the shop performing the repair must authorize the work to be done. In Saskatchewan, most vehicles are appraised by Saskatchewan Government Insurance (SGI) and a printed estimate is provided to the owner of the vehicle. The owner then takes the estimate to an autobody shop. The owner must be aware of the portion of the bill for which he/she may be responsible. If, during the repair, damage that was not included in the original estimate is found, do not continue with the work until authorization for the additional repairs has been obtained from all parties. Sometimes a decision to replace rather than repair is more cost efficient. Estimates must include allowance for additional time for: setting up the vehicle on a frame-straightening machine accessing (pushing, pulling or cutting) damaged parts straightening and aligning parts removing undercoating repairing corrosion to adjacent parts removing parts that are encrusted with rust drilling mounting holes filling unneeded holes in parts repairing a replacement part doing suspension or wheel alignment removing damaged glass applying sound-deadening material restoring corrosion protection removing and replacing accessories (trailer hitch, sun roof, roof rack, mirrors, fender flares, etc.).
12.3 To determine the extent of the damage. (NUM, CCT)	Most appraisers start from the outside of the vehicle and work inward, listing everything by section that is bent, broken, or missing. Conditions to look for include: direct body damage at point of impact improper alignment of body parts hidden structural damage to outer body panels (cracked undercoat or sealer indicates structural damage) indirect damage from shock wave traveling through parts mechanical damage to engine, drive train, suspension, etc. interior damage (air bags deployed, dash damage, etc.) bent wheels damaged tires broken glass broken mirrors.
12.4 To identify conditions that make the vehicle a total loss. (CCT)	Total loss occurs when the cost of repairing the vehicle exceeds the market value of the vehicle. Owners may wish to have a third party assess the market value of their vehicles if they do not agree with the value suggested by the insurer. Consider a work study placement or a field trip to an autobody shop or a placement with a mentor working as an insurance damage estimator, in order to see several appraisals done. Encourage career development discussions.

Module 13: Automobile Refinishing and Repainting (Optional)

Suggested time: 35-40 hours Level: Introductory

Module Overview

Students will learn the procedures for preparing and painting automobile surfaces. Topics include refinishing, sandpapers, feather edging, paint removal, thinners and reducers, metal preparations, paint guns, air compressors, regulators, air lines, spray booths, using a spray gun, types of primers and uses, types of sealers and uses, types of paint and uses and masking and removal of masking.

Foundational Objectives

To understand the appropriate use, care and maintenance of tools used for autobody repair.
To estimate technical measurements, recommend procedures and select appropriate products for use in autobody repair.
To handle, use and dispose of materials safely.

Common Essential Learnings Foundational Objectives

To learn industry-related vocabulary and use it in context. (COM)
To understand and practise the safe handling of hazardous materials. (TL)
To develop the willingness and confidence to make decisions and proceed with necessary repairs. (IL)

Note: Other CELs may be emphasized.

Learning Objectives	Notes
13.1 To understand the steps required to refinish and paint part of an automobile. (COM, TL)	Review the steps involved in refinishing an automobile and explain the many procedures and products as follows: wash the car to see any imperfections clean the inside of the car clean the surface of the car with a quality wax and grease remover (paint products will not adhere to wax or grease) feather edge all broken edges on the painted surface (e.g., stone chips, scratches, areas where body work was done and all edges on the automobile, around glass areas, etc.) sand the whole automobile rough mask the automobile where it is to be primed metal prep all bare metal areas apply vinyl wash primer to all bare metal areas prime all bare metal areas, feather edged areas and body work areas body putty any scratches or marks that the primer will not fill block sand body work and primed areas to get rid of waves in the body work reprime any area that needs it (e.g., waves, bare metal, etc.) sand the whole car and remove all masking blow off all dust inside and out until clean mask the whole car wet down the paint booth and move the car in; blow dust off the car again wipe the whole car with a high quality wash and wipe (wipe with a tack rag to remove any lint) apply colour coats.
13.2 To choose the correct type and grit of sandpaper for the job.	Discuss: grit number, wet and dry sandpaper, direction to sand an automobile, grit of sand paper to start with and grit to end with. Refer to resource materials for more detail. Sandpaper is used to rough up the surface of the paint so the top coats will have something to adhere to and to sand down the primer so that it will fill any scratches in the surface. An automobile is always sanded back to front or horizontal to the ground. Start with 320 grit to cut down the surface so the primer will adhere.
13.3 To remove paint from a surface. (TL)	Explain that the grit of sandpaper for final sanding depends on what type of paint is being used. For example, if the paint used is acrylic enamel, 400 grit to 600 grit should be used so as not to create any sand scratches. Color tends to magnify any imperfection under it. Therefore, if black or a dark colour is used, 600 grit should be used instead of 400 grit. Removal of paint can be accomplished with a paint remover, by sandblasting, or by grinding. Demonstrate how paint remover is used safely. Rubber gloves, safety glasses and a respirator must be worn.
13.4 To feather edge imperfections in a painted surface. (TL)	Demonstrate how the sandblaster works and how it removes paint from the surface by shooting it with sand at high pressure. The feather edger is used to taper the broken edges of paint so they cannot be seen or felt. Refer to resource materials for detailed information about correct use.
13.5 To understand the use of reducers and thinners.	Reducers and thinners are used to thin paint to spraying viscosity and for cleaning up paint materials and equipment. A reducer is a petroleum product used to thin enamels and polyurethanes to the appropriate spraying viscosity. Thinners are used to thin lacquers to spraying viscosity and for cleaning paint materials and spraying equipment. Refer to resource materials and manufacturer’s information sheets for detailed information. (IL)
13.6 To understand the use of metal preps.	Metal prep is a phosphoric acid used to clean and etch bare metal of flash rusting and to insure that no rust will develop before applying vinyl wash primer. Refer to resource materials and manufacturer’s information sheets for detailed information.
13.7 To understand how a paint gun works and the various types that are in use in body shops. (TL, COM)	Use a diagram to discuss the parts of a spray gun (gun body, air cap, air horns, fluid tip, needle valve and packing, fluid adjustment, spreader adjustment, trigger, air valve, fluid inlet, air inlet) and how they work. Discuss the different types of spray guns on the market (suction feed, pressure feed, gravity feed and HVLP). Demonstrate the safe use of a suction feed spray gun and spraying technique. Refer to resource materials for detailed information.
13.8 To be knowledgeable about the use of air compressors, air hoses and air regulators (transformers). (TL)	The student will become familiar with and be able to identify the major parts of the compressor and understand air pressure drop in relation to the length of line used. It is important to know that the byproduct of compression is water that must be drained off regularly so as not to get into the air tools or paint gun. If that is not done, the results can be costly in repairs to tools and a ruined paint job. Refer to resource materials for more information. Make arrangements to use a local autobody shop if the equipment is not available in the school. Community projects or work study are possibilities.
13.9 To describe the types of spray booths used and their advantages.	A spray booth is used to isolate the vehicle while painting it. It provides a clean area in which to paint an automobile and provides a safe area to contain the overspray and paint fumes that are explosive and toxic. See resource materials for descriptions of the various types of spray booths.
13.10 To understand the use of primer and spray primer on the surfaces to be refinished and painted.	Discuss the many different types of primer on the market today. It is not necessary to have used them. Vinyl wash primer is sprayed on bare metal to promote adhesion for the primer coat that follows. Primer is used to fill scratches and minor imperfections in the surface and to give the paint something to adhere to.
13.11 To understand the use of sealers and how to apply them.	Demonstrate how to spray primer. Primer is applied only on a surface that is clean, dry and free of oil and wax. Explain the functions of sealers. Sealer is used to: make the car one colour (easier to cover or hide the undercoats) reduce sand scratch swelling (fresh paint tends to swell sand scratches) provide even holdout so the new paint will not sink into the old substrate. Sealers are always used immediately under the top coat only. Explain the functions of body putty. Body putty is used to fill scratches and imperfections that primer cannot fill. Outline two main types of body putty: air dry (It dries at room temperature; sands and fills very well, but should not be used under two part paint and putty.) two part putty (This type of putty needs a hardener to cure. It dries very fast and sands and fills extremely well. It should only be used under two part paint and putty.).
13.12 To be knowledgeable about the different types of automotive paints on the market and their uses. (TL)	Types of automotive paints include: Acrylic lacquer (seldom used in the automotive industry). Acrylic enamel (uses a hardener to cure and dry and an enamel reducer to thin to spraying viscosity. It needs 3 coats to cover and shine well but dries in about 24 hours. It is very durable, stands up to weather elements and is easy to maintain). Polyurethane (uses a hardener to cure and dry; uses a reducer to thin to spraying viscosity; dries in about 10 hours; needs only two coats to cover and shine well; often called the wet look; is very durable; stands up to weather elements; and is easy to maintain). Base coat/Clear coat. Base coat is used as the colour; clear coat is used to cover the base and give it a high durable shine. NOTE: Wear a fresh air mask when applying any of the above paint products. When demonstrating painting, the teacher should use enamel or lacquer products, as they are reasonable in price and yet give the student practice with the spray gun technique.
13.13 To mask for painting part or all of a vehicle and to remove masking upon completion of the painting. (TL)	Masking is used to cover anything that is not to be painted. The best method used in masking is the paper-tape method. It does not collect dust and dirt easily and is easy to keep clean. Demonstrate how to make a straight line with masking tape and to cover only the trim piece to be protected. Over-masking or under-masking can ruin a paint job. Once the automobile has been painted and is dry, the masking shall be removed slowly and at right angles to the surface that was painted so as not to damage or pull off the paint.
13.14 To prepare the different types of automotive paints for use.	Mix various types of paints according to manufacturers instructions. When mixing paints, students must wear rubber gloves, a respirator and work in a well-ventilated area.
13.15 To apply the different types of automotive paints.	The students must learn to regulate the air pressures for application. The student must also be able to set the paint gun. Note: students must wear proper attire and a respirator for painting.