Module 16: Advanced Metal Repair (Core)

Autobody 10, A20, B20, A30, B30 Main Menu

Module 16: Advanced Metal Repair (Core)

Suggested time: 15-25 hours Level: Intermediate

Module Overview

Students will review basic autobody metal repair. They will then assess damage. Using dent pullers, suction cups and hydraulic tools, they will straighten metal panels. Students will learn to use body filler, lead and fiberglass products to produce smooth contours on vehicle panels. It is recommended that students have completed Module 5: Metal Straightening and Module 6: Filling Damage.

Foundational Objectives

To understand the appropriate use, care and maintenance of tools used for autobody repair.
To develop procedures for the safe use of tools and equipment.
To estimate technical measurements and time for repair and recommend repair procedures.

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 choose tools, products and procedures appropriate for the work required. (TL, CCT)

Note: Other CELs may be emphasized.

Learning Objectives	Notes
16.1 To identify and use hand tools and common power tools used for autobody repair and to perform basic metal straightening procedures. (TL, COM)	See Module 3: Hand Tools, Module 4: Power Tools, Module 5: Metal Straightening and Module 6: Filling Damage. Review body hammers, on dolly blows, off dolly blows, pulling tools, picking tools, cutting tools, checking contours, shrinking, etc.
16.2 To use body fillers.	Review using body fillers, mixing body fillers and filling to contour.
16.3 To identify the direct and indirect damage to a panel. (TL, CCT)	Direct damage is the damage in the impact area. Indirect damage is the damage spreading away from the point of impact. It is important to identify all damage in order to execute a repair in correct order and to estimate accurately the cost of repair. Damage is always removed in the reverse order from which it occurred. Work from the least damage to the worst damage. Working in this sequence, materials will begin to flex back to their original shape. Straightening should not be attempted until glass, trim, etc. has been removed. Major damage may require the use of one or more of the following: picking tools, dent pullers, body spoons, suction cups and hydraulic rams. Be sure that students have the opportunity to use all of these tools. Use a community project or a work study.

Learning Objectives

Notes

16.1 To identify and use hand tools and common power tools used for autobody repair and to perform basic metal straightening procedures. (TL, COM)

See Module 3: Hand Tools, Module 4: Power Tools, Module 5: Metal Straightening and Module 6: Filling Damage. Review body hammers, on dolly blows, off dolly blows, pulling tools, picking tools, cutting tools, checking contours, shrinking, etc.

16.2 To use body fillers.

Review using body fillers, mixing body fillers and filling to contour.

16.3 To identify the direct and indirect damage to a panel. (TL, CCT)

Direct damage is the damage in the impact area. Indirect damage is the damage spreading away from the point of impact. It is important to identify all damage in order to execute a repair in correct order and to estimate accurately the cost of repair.

Damage is always removed in the reverse order from which it occurred. Work from the least damage to the worst damage. Working in this sequence, materials will begin to flex back to their original shape.

Straightening should not be attempted until glass, trim, etc. has been removed.

Major damage may require the use of one or more of the following: picking tools, dent pullers, body spoons, suction cups and hydraulic rams. Be sure that students have the opportunity to use all of these tools. Use a community project or a work study.

Module 17: Panel Alignment (Core)

Suggested time: 15 hours Level: Intermediate

Module Overview

Complete panels often need to be replaced in order to repair a vehicle. This module deals with the alignment of the hood, doors, quarter panel and trunk lid of vehicles.

Foundational Objectives

To evaluate damage to motor vehicles in order to determine corrective work procedures.

Common Essential Learnings Foundational Objectives

To learn industry-related vocabulary and use it in context. (COM)
To choose tools, products and procedures appropriate for the work required. (TL)

Note: Other CELs may be emphasized.

Learning Objectives	Notes
To replace and align:
17.1 a hood on an automobile;	Refer to reference materials.
17.2 a door on an automobile;
17.3 a trunk lid on an automobile;
17.4 a fender on an automobile;	Consult a manual.
17.5 a quarter panel on an automobile. (COM, TL)	This is a major panel that is welded in place. Refer to resource materials for detailed directions.

Module 18: Glass Removal and Installation (Optional)

Suggested time: 10-20 hours Level: Advanced

Module Overview

Students will gain knowledge about types of glass, glass removal and replacement and the safe disposal of materials.

Foundational Objectives

To handle, use and dispose of materials safely.
To recommend procedures and select appropriate products for use in autobody repair.

Common Essential Learnings Foundational Objectives

To understand and practise the safe handling of hazardous materials. (TL)

Note: Other CELs may be emphasized.

Learning Objectives	Notes
18.1 To identify types of glass and retaining systems used in the automobile industry.	Tempered glass is heated and then cooled rapidly. This results in glass that has great strength and that breaks into small particles when broken. Laminated glass is made of two layers of glass that have a polyurethane layer between them. This is usually used for windshields. Impact results in cracks but the polyurethane layer holds the pieces of glass together so that occupants of the vehicle are not subjected to flying glass particles. Retaining systems vary with make, model and year of vehicles. Manuals should be consulted to determine the correct procedure for removal and replacement. Windshields are an integral part of the roof structure of modern vehicles and must be installed to specification in order to perform properly.
18.2 To understand the safe procedures for handling and disposing of glass and glass installation products. (TL, PSVS)	Gloves, long sleeved apparel and eye protection are necessary. Some installation materials may be hazardous and labels should be read to determine precautions that need to be taken. Clean-up and disposal of broken glass requires safe procedures. Installation varies. Refer to reference materials before preceeding. (TL)
18.3 To remove and replace front and back windshields on an automobile.	It is recommended that following these procedures, vehicles should remain overnight before being moved. Any movement may break the bond between structure and windshield. Non-moving side glass, can be retained in a variety of ways. Consult a manual when in doubt.
18.4 To replace side glass on an automobile. (TL, CCT)	When ordering side glass, be careful to note the tint. Manufacturers may vary tint by model and some windows have been tinted with after-market products. Refer to manuals for removal procedures.