Vehicle Body RepairseCollege

TRADE OF VEHICLE BODY REPAIR PHASE 2Module 6UNIT: 2Crash Repairs Produced by FS Learning Innovation UnitIn co-operation with Subject Matter Experts:Maurice Stack& CDX GlobalFENC Further Education National Consortium Foras iseanna Saothair 2006Table of ContentsIntroduction7Unit Objective8 Crash Repair81.0 Safety in Relation to Removing and Refitting of Non Structural Panels91.1 Jacking and Lifting92.0 Storage of parts Safely and Appropriately113.0 Dismantle Damaged Area on Vehicle123.1 Correct Assembly and Alignment of Panels123.2 Fits and Clearances133.3 Front End/Bodyside Clearances143.4 Rear End Clearances154.0 To Carry out Repairs on Non Structural Panels as per Estimate174.1 The Importance of Preparation and Cleaning before Repair175.0 Removing Causes of Corrosion205.1 Repairing Rust Damage205.2 Part Panel Joining Techniques (Patching) and Removing Causes of Corrosion215.3 Structured Repair Procedure225.4 Sealing-Waxing of Panels and Welded Joints235.5 Awareness of the Presence of Airbags, Ribbon Bags, Seat Belt Tensioners and Other Safety Devices286.0 Safety Service and Storage of Airbags296.1 Side Impact Protection System476.2 Description of Components576.3 Recovery of Vehicles Containing Airbags617.0 Emergency Rescue from Vehicles with Airbags627.1 Vehicle Crash Procedures628.0 Vehicle Crash Fire Prevention Procedures70Summary74Self Assessment75Suggested ExerciseTraining ResourcesTable of FiguresFigure 1: Jacking and Lifting10Figure 2: Front Bumper Removal12Figure 3: Fits and Clearances13Figure 4: Fits and Clearances13Figure 5: Front End and Bodyside Clearances14Figure 6: Rear End Clearances15Figure 7: 1989 Mini Frame16Figure 8: Remove Coating near Weld17Figure 9: Removing E Coat Primer from a new Panel18Figure 10: Using Paint Stripper on a Galvanised Panel19Figure 11: Using a Special Sander on a Galvanised Panel19Figure 12: Repair Patch21Figure 13: Airbags28Figure 14: Seatbelts - Mondeo Vehicles34Figure 15: Seatbelts Granada Scorpio Models34Figure 16: Seatbelt Buckle Pre-Tensioner System35Figure 17: Head of Buckle36Figure 18: The Ford Supplementary Restraint System37Figure 19: Pyrotechnic Seatbelt Pre-Tensioner37Figure 2039Figure 21: Airbag with the Locations of the Various Components41Figure 22: At the point of impact the driver is still in his normal position43Figure 23: Gas Generator45Figure 24- 25: The driver plunges into the cushion45Figure 26: The Airbag Starts to Collapse46Figure 27: Driver is Back into Original Position46Figure 28: SIPS Bag47Figure 29: Senor Unit47Figure 30: Gas Generators49Figure 31: The SIPS Bag50Figure 32: Sensor Unit51Figure 33: Unlock SIPS Bag51Figure 3452Figure 3552Figure 36: Remove Front Seat53Figure 37: Unlock SIPS Bag54Figure 38: Data for SIPS Bag55Figure 39: Installing Sensor Unit55Figure 40: Installimg SIPS Bag Cushion Module56Figure 4157Figure 42: Steering Column57Figure 43: Airbag58Figure 44: Neoprene Coated Airbag58Figure 45: Contact Unit59Figure 46: Instrument Display61Figure 47: Information Label64Figure 48: Eurobag Components66Figure 49: VIN Plate71Module 6 Unit 2IntroductionDamaged body work is corrected by first observing the extent of the damage, then deciding how it was caused and the sequence in which it occurred. The resulting damage can be classified into two groups:Direct or Primary Damage This results from the impact on the area in actual contact with the object causing the damage. This will result in the largest area of visible damage and is the cause of all other consequent damage. Primary damage is identified by first determining the direction of the primary impact. This knowledge will help in the search for concealed damage.Indirect or Secondary Damage This is usually found in the area surrounding the direct damage which causes it; although in certain cases it may be some distance from the actual point of impact.Non Structural PanelsIn general non structural panel is a panel that can be removed easily and is fastened by bolts, screws, clips or spot welds. Such panels do not form an integral part of the body shell.Unit ObjectiveCrash RepairBy the end of this unit each apprentice will be able to: Dismantle damaged area on vehicle Store parts safely and appropriately Carry out repairs on non-structural panels as per estimate Re-finish and assemble removed parts completely and securely Determine the level of corrosion Carry out suitable repair (patching) and ensure no recurrence of corrosion Key Learning Points: Safety in relation to removing and refitting of non-structural panels Importance of preparation and cleaning before repair Structured repair procedure Selection of tools, MIG and spot welding equipment and materials Economic use of materials, paints (blending, etc.) Use of materials in a correct and safe manner Correct assembly and alignment of panels Repair assessment on activities carried out Preparation techniques (patching) Removing causes of corrosion Sealing-waxing of panels and welded joints Natural or forced air ventilation. Ventilation drain holes Health and safety. Proper breathing apparatus goggles gloves supplied Fire hazards check for flammable materials near repair area Awareness of the presence of airbags, ribbon bags, seat belt tensioners and other safety devices. 1.0 Safety in Relation to Removing and Refitting of Non Structural Panels1.1 Jacking and LiftingGarage JackingTrolley JackWhen raising the front of the vehicle, locate a trolley jack beneath the front toeing eye at A in Fig 1. At the rear, place the trolley jack below the towing eye at D.Vehicle LiftsWhen raising a vehicle on a wheel free lift, locate the lifting arms at the standard jacking points B and C.Axle StandsLocate axle stands beneath the standard jacking points B and C. Never work without axle stands.When raising and supporting the vehicle at points A and B it is necessary to use the suitable hard rubber pads in conjunction with the lifting heads to reduce the risk of vehicle damage.Figure 1: Jacking and Lifting2.0 Storage of parts Safely and Appropriately3.0 Dismantle Damaged Area on Vehicle Dismantle parts in a safe manner Put all bolts/screws in a container Store parts appropriately and safely Re- assemble in reverse order3.1 Correct Assembly and Alignment of Panels Figure 2: Front Bumper RemovalFront Bumper Numerical Order of Removal1Raise vehicle and remove 2 off scrivets (1 each side) securing wheel arch liners to wings front)4Remove 2 off lower bolts securing bumper to front crossmember and 4 off scrivets (2 each side) to release bumper from bonnet landing panel2Release wheel arch liners and remove 2 off screws (1 each side) securing bumper to wings front5Release bumper and disconnect fog lamp connectors. (if headlamp washers fitted, release clip and disconnect power wash hose)3Remove 2 off lower bolts (1 each side) securing bumper to wheel arch liners6Protect paintwork and remove bumper3.2 Fits and ClearancesFigure 3: Fits and Clearances Figure 4: Fits and Clearances1. Bumper/Wing2. Wing/Door FR3. Door R/Door FR4. Door R/ Panel 5. Panel/Boot Door6. Bonnet/Wing3.3 Front End/Bodyside ClearancesFigure 5: Front End and Bodyside ClearancesFront SectionGapGap DescriptionDimension (mm)ProfileDimension (mm)A-AaGrille to Bumper8.0 1-B-BbBonnet to Bumper5.5 + 3 to 0-C-CcBonnet to Bumper Headlamp Trim5.5 +2 to 0 -D-DdWing Front to Bumper2.5 1.0 -E-EeBonnet to Wing Front3 + 1.0 to -0.5-Front SectionGapGap DescriptionDimension (mm)ProfileDimension (mm)F-FfWing Front to Door Front 5.5 0.5Wing Front to Door Front0 + 0 to -1G-GgDoor Front to Door Rear5.5 0.5Door Front to Rear Door0 + 0 to -0H-HhDoor Rear to Wing Rear4.5 + 0.5Door Rear to Wing Rear0 + 1 to -0J-JjBumper Rear to Wing RearBumper Rear to Wing Rear1.0 + 0.5 to 1.03.4 Rear End ClearancesFigure 6: Rear End ClearancesRear SectionGapGap DescriptionDimension (mm)ProfileDimension (mm)K-KkTailgate to Wing Rear4 + 1 to -0.5Tailgate to Wing Rear0 +0 to -1.0L-LlTailgate to Roof18.5 + 1 to -0.5Tailgate to Roof-6.6 + 1. to 0.5M-MmTailgate to Rear Lamp4.0 + 1.0 to -0.5Tailgate to Rear Lamp0.6 1.0N-NnTailgate to Bumper Rear7.0 + 1.0 to -0.5 Tailgate to Bumper Rear0 1.0 O-OwFuel Flap3 + 0.5Fuel Flap to Wing Rear at Front Edge Fuel Flap to Wing Rear at Rear Edge0 0.50 + 0.5Figure 7: 1989 Mini Frame To avoid wind noise the wing must be fitted 0.5mm outside the door AA. The door must be 0.5mm outside the panel BB and so on. The bonnet and wings with left flush CC the same applies to the boot lid.1. Wing2. Door3. Panel4.0 To Carry out Repairs on Non Structural Panels as per Estimate4.1 The Importance of Preparation and Cleaning before Repair It is important to remove rust, Galvanised coatings and loose material before commencing and repair. Sand blast area surrounding the repair and remove metal that is pitted and replace by patching.Figure 8: Remove Coating near WeldPrepare New Panel (Non-Galvanised) Clean Welded Surfaces of Flanges and JointsPrior to carrying out MIG welding or resistance spot welding on a new panel it is necessary to remove the E coat primer from the panel, to promote good electrical current flow.Using a rotary wore brush, or a sander fitted with a disc of up to 50 grit maximum, remove the primer from both sides of the panel joint if resistance spot welding and one side only where MIG welds are to be made.Health and Safety: PROTECT YOURSELF FROM HARM!Figure 9: Removing E Coat Primer from a new PanelWhen using a sander, do not grind into the panel surface.When sanding, do not work-heat the panel to the point where it turns blue or begins to warp.Where specified by the manufacturer, ensure that the inner surfaces of the outer panels such as front and rear wings, front and rear panels, sill panels, etc. are top coated before welding.Prepare New Panel (Galvanised) Clean Welded Surfaces of Flanges and JointsWhen preparing a galvanised panel, it is important to ensure the zinc coating is left intact and the panel prepared according to the manufacturers instructions.Remove the E coat primer using either a suitable paint stripper and a scraper or a special sanding medium formulated for the purpose.Do not use any other abrasive material for this purpose. Remember: galvanised panels must be treated differently.Figure 10: Using Paint Stripper on a Galvanised PanelFigure 11: Using a Special Sander on a Galvanised Panel 5.0 Removing Causes of Corrosion5.1 Repairing Rust DamageIn this work the body repairer relies on his own judgement, skill and experience. Rust is a corrosion, known chemically as iron oxide and occurring after exposure to air and moisture, on the surface of iron and the majority of its alloys. In the past the construction of all-steel body shell contained numerous cavities and crevices within the structure which tended to retain moisture carrying matter, thus creating suitable conditions for the rusting process. Rust attacks in particular wings, sill panels, wheel arches, floor of luggage compartments and bottoms of doors, the worst being the sill because of their close proximity to the road. During the past few years some manufacturers have made improvements which have reduced the rusting of bodies. In some cases this has been achieved by good design and in other cases by treating metal prior to painting. The method of repairing rust damage depends upon the extent of the corrosion within the panels, giving the body repair worker a choice between two alternatives methods of repair. The best possible results are obtained by the total removal of all corroded sections, replacing them with either new panels when available or handmade panels or sections when not readily available or cost is restricted. The replacement panels can be fitted by welding them into position and finishing planishing, filing and sanding. In the case of older vehicles where new panels are not available or where the vehicles age or condition make it uneconomical to fit new panels, the method of fabricating or patching these areas, by cutting out and replacing these section from flat sheets fabricated by hand, is adopted. In many cases if the original sections are carefully cut out and not too distorted, they can be used as an excellent guide to manufacture of new sections. Templates can also be made up before the old sections are cut out to check alignment and curvature when fitting the new section. Often double curvature panels such as wheel arch fabrications must be made up in two or three parts for ease of patching onto the original body. The main difficulty experienced in this type of repair is the welding of the new metal onto the old: this is one of the reasons why it is important to cut away all the rusted section so that the new metal can be welded to a rust free section. In cases where the sections are vary badly corroded and welding is difficult, the section can be cleaned of surface rust and sometimes brazed to form the joint. The second method of rust repair, which is only a temporary measure and not recommended for longevity, is to fill the corroded section with either body solder or chemically hardening filler. If the corrosion is only very slight, giving a pinhole effect, the area can be sanded down to bare metal, hammered down carefully to below its original level and then filled up with body solder and filed to a finish. Plastic filler should not be used in this case because the moisture would seep through, parting the filler from the panel. Where the corroded area has turned to holes it can only be repaired by placing a patch over the corrosion and welding or brazing it in place. This patch level is then filled with body solder or plastic filler to obtain the final finish. In some cases where it is difficult to weld a patch, the perforated section can be reinforced by using glass-fibre matting impregnated with resin and bonded to the underside of the repair. The surface can then be filled with plastic filler and finished by filing. 5.2 Part Panel Joining Techniques (Patching) and Removing Causes of CorrosionWhen repairing cut away rust and put a flanged patch behind it, weld in place be sure to continuous weld as it seals joint from moisture.Figure 12: Repair Patch5.3 Structured Repair Procedure Selection of tools. MIG and spot welding equipment and materials Move the vehicle into place and secure safely Move tools into place Collect all parts for the job Plan your repair sequence Structure your time Remove damaged parts that need replacing Carry out repairs on repairable parts Prepare new parts, prime and paint and refit Prepare required parts, prime and paint Use of materials in a correct and safe manner. See Health and Safety Mod 5 Spray Painting (COSHH)(SMDS) Health and Safety. Proper breathing apparatus, goggles, and gloves suppliedSpray Suit and 3mm Mask Spray suit Air Fed Mask Fire hazards. Check for flammable materials near repair area. Se introduction, Mod 1, unit 2 Economic use of materials, paints (blending, etc.) Sealing-waxing of panels and welded joints Repair assessment on activities carried out5.4 Sealing-Waxing of Panels and Welded JointsMetal to Metal. Metal to Plastic Bonding. Use of plastic panels on vehicles is on the increaseE.g. Citroen, Renault, Audi spare wheel well etc. Plastic cannot be welded to metal. It must be bonded. Terokal 2K-PUR, Teromix 6700. Developed by Teroson for this purpose. The product is also ideally suited to Metal to Metal applications. Three Cs - Clean, Compact and Correct. Advantages: Ideal for non-structure parts e.g. door skins, roof skins, rear wheel arches, window panels on vans/jeeps etc.Can be used where metal welding is difficult or dangerous i.e. near petrol tank, windscreen panels.No heat warping of panels.Complete seam is sealed and protected, unlike welding.2-Pack material, curing time very fast with heat.Can be spot welded or clamped when applied.Can be sanded and over-painted once dry.Sound DeadeningVehicle NoiseVibration soundTerodem SP100Aluminium Backed Bitumen Application: DoorsSize: 550mm X 250mmTerodem SP300Heavy-duty, Large Bitumen boards,Mallable with heat. (Self-adhesive)Application: FloorsSize: 500mm X 500mmAnd 1000mm X 500mmTerodem SP200Soft self-adhesive sound deadening with polyurethane skin. Absorbs sound waves. Flame proof. Application: Under Bonnet. Size: 1000mm X 500mm.Sprayable Sound Deadening9320 Sprayable Sealer Trotex 2000/3000Underbody Coating / Rust ProtectionHistory of protectionBitumenPVC WaxManufacturers Warranty on Repair WorkQuality of MaterialsMaterial Base/ CompatibilitySolid Content Over-paintingUpol Gravitex Black/Grey/WhiteUnder Body Sealer Wurth Underbody protection Black Cavity Protection Wax Cavity Protection Wax Gun Air Operated C.P.W Gun in use Under Body Wax Sealer Black Hand Sealer GunC.P.W Pistol Gun5.5 Awareness of the Presence of Airbags, Ribbon Bags, Seat Belt Tensioners and Other Safety DevicesAirbagsFigure 13: Airbags6.0 Safety Service and Storage of AirbagsGeneral Safety and Storage of Explosive DevicesIt must be observed that the airbags and explosive seatbelt tensioners which are now fitted to an increasing number of vehicles are affected by UK Legislation, namely the Explosives Act 1875 to 1976. The Act applies to the storage of these devices as they are fitted with explosive triggers to allow them to operate, with obvious safety implications. In addition to the points made on the following pages, which relate specifically to the service and operation procedures on airbags as fitted to Vauxhall and Ford passenger cars, the following points MUST be noted with regard to the general workshop storage of explosive devices:The explosive devices used fall within the requirement of the Explosives Acts 1875 to 1976. Because of this, your premises must be registered for keeping Gunpowder/Mixed Explosives. Contact your relevant local County Council Department for details of local requirements.Ensure that steering wheels/steering column assemblies containing un-deployed airbags are clearly labelled with the job number and the date placed in storage, and a log kept by a responsible person giving this information. In addition, the name of the person placing the device in storage and removing it from storage must be recorded. This procedure must also be followed with seatbelt tensioners fitted with explosive devices.Obtain the relevant vehicle Manufacturers information concerning recommended procedures when working on a vehicle fitted with explosive devices. In certain cases it may be found that disconnec