Auto Body Repair and Radiator Repair Course
on CD

TABLE OF CONTENTS

Lesson 1: Task 1: BODY and FRAME REPAIRS

1.Introduction

2.Body Construction
- - Body Construction
- - Roof Panel Assembly
- - Floor Pan Assembly
- - Rear Quarter Panel
- - Doors
- - Deck Lid

3.Frame Construction
- - A typical passenger car frame
- - Metal repair procedures and straightening and squaring
- - Surfaces to be welded
- - Spot weld repairs
- - Straighten crossmembers
- - Commercial vehicle frames
- - Riveted parts

4.Metal Body Trim and Hardware
- - Trim
- - Grilles
- - The inside garnish molding
- - Handles
- - Door Trim Pads

5.Metal Body Tools
- - Body Hammers
- - Dollys
- - Body Spoons
- - Quarter Panel Spoon
- - Caulking Iron
- - File Holders and Blades
- - Maple Solder Paddle

6.Metal Body Equipment
- - Hydraulic Body Jack
- - Direct Acting Jack
- - Remote Controlled Jack
- - Remote Controlled Jack Components
- - Electric Disk Sander

7. Measurement Principles
- - Comparative Measurement
- - X- - checking measurement

8.Body and Fender Repair Techniques
- - Analyzing Damage
- - Roughing and Aligning
- - X - CHECKING FRAME
- - Hammer Finishing
- - Direct Hammering
- - Indirect Hammering
- - Spring Hammering
- - Pick Hammering
- - Metal Shrinking
- - Hot Shrinking
- - Cold Shrinking
- - Using the Body File

PRACTICAL EXERCISE 1

PRACTICAL EXERCISE 1 - ANSWERS



LESSON 2 : GLASS, RADIATOR, AND FUEL TANK REPAIRS

TASK 1. Describe the operations required for proper glass repair.

1.Introduction

2.Glass - Composition and Characteristics
- - Lead Class
- - Lime Glass
- - Plate Glass
- - Window Glass
- - Tempered Glass
- - Bulletproof Glass
- - Laminated Safety Class

2.Removal of Vehicle Glass
- - Glass Cutting
- - Cutting the plastic between the sheets of glass

3.Glass Grinding and Finishing.

4.Installing Glass.


TASK 2. Describe the operations required for proper radiator repair.

1.Introduction
- - Radiator Construction
- - Water Tanks
- - Radiator Fittings
- - Tubular Core
- - Honeycomb Core

2.Radiator Cleaning
- - Flow Testing
- - Pressure Flushing
- - Boiling Out Radiators
- - Cleaning Solution
- - Rod Cleaning

3.Testing Radiator for Leaks
- - Visual Inspection
- - Air test
- - Field Test Tank
- - Marking Leaks

4.Radiator Disassembly
- - Side Member Removal
- - Upper Tank Removal
- - Lower Tank
- - Filler Neck
- - Inlet Pipe
- - Baffle Plate
- - Outlet Pipe
- - Drain Cocks

5.Radiator Assembly
- - Soldering
- - Tinning compound
- - Flux hydrochloric acid
- - Soft solder
- - Ideal torch flame

6.Repairing Radiator Leaks
- - Seam Leaks
- - Tubular Core

7.Straightening a Bent Radiator Core

8.Repair of Aluminum Radiators
- - Repair Procedures for End Tanks
- - Repair Procedures for Cores
- - Cleaning and Painting
- - Noninsulating paint


TASK 3. Describe the operations required for proper fuel tank repair

1.Types and Construction
- - Fuel Tank Body and Ends.
- - Fuel Tank Fittings
- - Filler Neck
- - Filler Tube (sleeve) Assembly
- - Filler Cap
- - Fuel Pickup Connection Plate
- - Fuel Gage Connection Plate
- - Drain Plug

- - Fiberglass Fuel Tanks

- - Cell or bladder - type tank

2.Repair Operations

3.Testing for Leaks
- - Cleaning
- - Live steam method
- - Exhaust- - and- - air method
- - Patching

Practical Exercise 2
Practical Exercise 2 - Answers
REFERENCES