Suggested time: 20-30 hours Level: Introductory
Module Overview
Students will practise using the various hand and power tools necessary in autobody operations.
Foundational Objectives
Common Essential Learnings Foundational Objective
Note: Other CELs may be emphasized.
| Learning Objectives | Notes |
|---|---|
| 5.1 To rough the metal to a prescribed contour with the use of an all-purpose dolly. (TL) | Check the contour of the metal using a template. Use the all-purpose dolly and light dinging hammer to raise small low areas. |
| 5.2 To raise the metal to a crown using the template as a pattern. | Check the shape of the contour frequently with both the template and hands for high and low spots. Refer to resource materials for a full description of on dolly and off dolly methods. |
| 5.3 To remove minor low spots in the metal using an all purpose dolly in conjunction with a flat-faced hammer. | |
| 5.4 To examine the metal to detect what a stretched area feels and looks like and how to shrink the area. (CCT, TL) | Shrinking is used to remove any stretched areas on the sheet metal as a result of damage. Refer to resource materials for detailed information. |
| 5.5 To file sheet metal with a steel body file to show up high and low spots in the metal. | Refer to resource materials for detailed information about filing sheet metal. |
Module 6: Filling Damage (Core)
Suggested time: 4-6 hours Level: Introductory
Module Overview
Students will learn how to fill a damaged area with body filler.
Foundational Objectives
Common Essential Learnings Foundational Objective
Note: Other CELs may be emphasized.
| Learning Objectives | Notes |
|---|---|
| 6.1 To grind the area with a disc sander. (TL) | Demonstrate how the area to be filled must first be roughed with a disc sander using a 24 grit disc to ensure that the body filler will adhere to the metal properly. A particle mask, eye and ear protection must be worn. |
| 6.2 To estimate how much body filler is needed to fill a given area. (NUM) | Discuss how the amount of body filler needed depends on the amount of damage. |
| 6.3 To estimate how much hardener is needed to set a given amount of body filler. | Mix the body filler with the desired amount of hardener using the product manufacter’s guidelines (usually a 10 cm puddle of filler to a 3 cm strip of hardener) on a scrap piece of metal or plastic plate. Note that the body filler is all one color when well mixed. (Hardener is coloured to show it has been mixed in to the body filler.) Rubber gloves must be worn when mixing and applying body fillers. |
| 6.4 To mix the hardener and the body filler. | Demonstrate how to spread the body filler over the damaged area with a 12 cm putty knife to create a smooth appearance giving it the appearance of a finished panel. |
| 6.5 To spread the body filler over the damaged area. (TL) | Students must wait until the body filler has cured before it is ready to file. This can be done with the finger nail test (e.g., if your finger nail catches and digs into the body filler, it is too soft to file; if your finger nail only marks the body filler and does not dig into the body filler, it is ready to file with a steel file). |
| 6.6 To file the body filler with a steel file and a sandpaper file to the desired contour. | Demonstrate with a steel file how to cut the body filler close to the contour of the panel. Demonstrate how to cross file to get the true contour of the panel. Demonstrate how to sandpaper file the surface with 40 grit sandpaper until the surface is smooth. Finish filing the area with 80 or 120 grit sandpaper to smooth and cut down the 40 grit scratches. Students will usually have to refill where necessary and refinish to produce a repair that follows the true contour. (CCT) The area is now ready to be refinished. |