| Preface |
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xii | |
| 1 Car body construction |
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1 | (10) |
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1 | (1) |
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2 | (1) |
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Elements of vehicle construction |
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3 | (4) |
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Vehicle information code plate |
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7 | (1) |
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Brief history of the motor vehicle |
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7 | (2) |
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9 | (2) |
| 2 Health and safety and the environment |
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11 | (20) |
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Personal health and safety procedures |
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11 | (3) |
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14 | (1) |
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Fire risks in the workshop |
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15 | (3) |
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Safety signs in the workshop |
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18 | (1) |
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General safety precautions in the workshop |
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19 | (1) |
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20 | (1) |
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21 | (1) |
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21 | (1) |
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Maintain the health, safety and security of the work environment |
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21 | (2) |
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Where identified hazards cannot be removed, appropriate action is taken immediately to minimize risk to own and others' health and safety |
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23 | (6) |
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29 | (2) |
| 3 Hand and power tools |
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31 | (21) |
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Hand tools used in body repair work |
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31 | (1) |
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31 | (2) |
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33 | (1) |
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34 | (1) |
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35 | (1) |
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36 | (1) |
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Specialist panel beating tools |
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36 | (1) |
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37 | (1) |
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38 | (1) |
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38 | (1) |
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39 | (2) |
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41 | (1) |
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41 | (1) |
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41 | (2) |
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Bending and swaging tools |
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43 | (1) |
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General-purpose assembly and dismantling tools |
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43 | (7) |
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50 | (2) |
| 4 Materials used in vehicle bodies |
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52 | (29) |
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52 | (9) |
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61 | (3) |
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64 | (2) |
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66 | (2) |
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Sound-deadening, thermal insulating and undersealing materials |
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68 | (1) |
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69 | (1) |
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70 | (1) |
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Amorphous and crystalline plastics |
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70 | (3) |
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Abbreviations for automotive plastics |
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73 | (1) |
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73 | (3) |
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76 | (1) |
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77 | (1) |
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77 | (2) |
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79 | (2) |
| 5 Metal forming processes |
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81 | (24) |
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81 | (4) |
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Heat treatment of steel and aluminium |
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85 | (6) |
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Machines for sheet metal fabrication |
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91 | (1) |
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92 | (2) |
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94 | (1) |
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95 | (1) |
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96 | (5) |
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101 | (2) |
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Sheet metal cutting for press work |
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103 | (1) |
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104 | (1) |
| 6 Marking out and measuring |
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105 | (15) |
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105 | (1) |
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106 | (1) |
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Basic marking-out and measuring instruments |
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106 | (8) |
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Precision marking-out and measuring instruments |
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114 | (4) |
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118 | (1) |
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118 | (2) |
| 7 Methods of joining |
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120 | (33) |
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120 | (1) |
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121 | (2) |
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123 | (4) |
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127 | (3) |
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130 | (1) |
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131 | (3) |
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134 | (6) |
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140 | (6) |
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146 | (1) |
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147 | (1) |
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Achieving good results with adhesives |
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148 | (1) |
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Adhesives and the automotive industry |
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149 | (2) |
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151 | (2) |
| 8 Soft and hard soldering methods |
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153 | (44) |
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Comparison of fusion and non-fusion jointing processes |
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153 | (1) |
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154 | (1) |
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154 | (5) |
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159 | (7) |
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Body leading/body soldering |
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166 | (1) |
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Health and safety and the environment |
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167 | (1) |
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168 | (1) |
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Gas welding, cutting and plasma arc |
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169 | (1) |
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169 | (1) |
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Oxy-acetylene welding equipment |
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169 | (3) |
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172 | (3) |
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Definitions of welding terms |
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175 | (1) |
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176 | (1) |
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Flame control and types of flame |
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176 | (2) |
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178 | (2) |
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Edge preparation and types of joint |
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180 | (1) |
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Welding technique: butt joint in mild steel |
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181 | (1) |
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182 | (1) |
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183 | (2) |
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Gases: characteristics and colour coding |
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185 | (2) |
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187 | (4) |
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191 | (4) |
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195 | (2) |
| 10 Electric resistive welding |
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197 | (16) |
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Resistance welding in car body manufacture |
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197 | (2) |
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199 | (1) |
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Resistance projection welding |
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200 | (1) |
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200 | (1) |
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201 | (1) |
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202 | (1) |
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Resistance welding in body repair work |
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202 | (1) |
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Resistance spot welding of high-strength steels |
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203 | (1) |
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203 | (4) |
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ARO Spotrite Pulsa resistance welding system |
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207 | (3) |
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Single-sided spot welding |
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210 | (2) |
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212 | (1) |
| 11 Manual metal arc welding (MMA) |
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213 | (16) |
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Principles of manual metal arc welding |
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213 | (1) |
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Electrical terms used in arc welding |
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214 | (1) |
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Metal arc welding equipment |
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215 | (3) |
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Electrodes used in welding: BS coding |
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218 | (2) |
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220 | (2) |
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Essential factors of arc welding |
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222 | (4) |
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226 | (1) |
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Safety precautions for the welder |
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227 | (1) |
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228 | (1) |
| 12 Gas shielded arc welding (MIG, MAG and TIG) |
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229 | (34) |
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Development of gas shielded arc welding |
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229 | (1) |
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Gases used for shielded arc processes |
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229 | (3) |
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232 | (6) |
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Application of TIG welding |
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238 | (1) |
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238 | (2) |
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MIG/MAG spot/plug welding |
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240 | (1) |
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Equipment used in MIG/MAG welding |
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240 | (6) |
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MIG/MAG welding techniques |
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246 | (5) |
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Applications of MIG/MAG welding in vehicle body construction |
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251 | (1) |
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Applications of MIG/MAG welding in body repair work |
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251 | (2) |
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MIG/MAG welding of low-carbon steel and HSLA steels |
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253 | (2) |
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Welding stress and distortion in the MIG/MAG process |
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255 | (4) |
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Weld testing and inspection |
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259 | (2) |
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Equipment maintenance and safety |
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261 | (1) |
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262 | (1) |
| 13 Craft techniques and minor accident damage |
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263 | (55) |
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Panel beating: forming panels by hand |
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263 | (1) |
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264 | (7) |
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General guide to the fabrication of hand-made panels |
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271 | (1) |
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Edge stiffening of sheet metal |
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272 | (3) |
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Techniques of damage rectification |
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275 | (2) |
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277 | (5) |
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282 | (1) |
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282 | (1) |
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283 | (3) |
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286 | (1) |
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286 | (2) |
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Chemically hardening fillers (plastic fillers) |
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288 | (1) |
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289 | (4) |
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Application of the body jack |
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293 | (3) |
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Repair of component motor body panels |
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296 | (7) |
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303 | (6) |
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Body electrical and electronic systems |
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309 | (2) |
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311 | (4) |
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315 | (3) |
| 14 Major accident damage repair |
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318 | (43) |
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Damage classification and assessment |
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318 | (1) |
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Pulling, alignment and repair systems used on major accident damage |
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319 | (5) |
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Alignment of the modem integral body |
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324 | (8) |
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332 | (27) |
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359 | (2) |
| 15 Bodyshop planning |
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361 | (30) |
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361 | (3) |
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Planning the areas of the workshop |
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364 | (5) |
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369 | (2) |
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371 | (2) |
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Essential equipment for the bodyshop |
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373 | (2) |
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Bodyshops and legal requirements |
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375 | (14) |
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389 | (2) |
| 16 Reinforced composite materials |
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391 | (32) |
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391 | (1) |
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Basic principles of reinforced composite materials |
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391 | (2) |
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Manufacture of reinforced composite materials |
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393 | (1) |
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Types of reinforcing material |
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394 | (4) |
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Resins used in reinforced composite materials |
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398 | (4) |
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Moulding techniques for reinforced composite laminates |
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402 | (13) |
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Repair of reinforced composite bodies |
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415 | (2) |
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Common faults in moulded laminates |
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417 | (3) |
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420 | (2) |
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422 | (1) |
| 17 Automotive finishing and re-finishing |
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423 | (56) |
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Glossary of terms used in spray painting |
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423 | (1) |
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Basic composition of paint |
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424 | (1) |
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425 | (1) |
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Materials used in refinishing |
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426 | (4) |
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430 | (2) |
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432 | (5) |
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Basic parts of a standard spray gun |
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437 | (1) |
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Spray gun maintenance and cleaning |
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437 | (2) |
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439 | (4) |
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443 | (2) |
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Sanding and polishing machines |
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445 | (2) |
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Preparation of a motor vehicle for repainting |
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447 | (2) |
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Finishing and refinishing processes |
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449 | (12) |
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Burnishing, polishing and final detail work |
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461 | (2) |
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463 | (1) |
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Movement of vehicle in the paint shop |
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463 | (2) |
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Common spray painting defects |
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465 | (2) |
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Colour mixing and matching |
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467 | (2) |
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Vehicle cleaning-detailing |
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469 | (7) |
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476 | (1) |
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477 | (2) |
| 18 Case study |
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479 | (5) |
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479 | (1) |
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479 | (2) |
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481 | (1) |
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482 | (2) |
| 19 Mechanical, electrical and trim-MET |
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484 | (14) |
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484 | (6) |
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490 | (1) |
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490 | (3) |
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493 | (1) |
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Quick reference guide to vehicle systems |
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493 | (2) |
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495 | (2) |
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497 | (1) |
| Appendix 1: Health and safety risk assessment and COSHH data sheets |
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498 | (21) |
| Glossary |
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519 | (9) |
| Index |
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528 | |
