For every task in Structural Analysis and Damage Repair, the following safety
requirement must be strictly enforced:
Comply with personal and environmental safety practices associated with clothing;
respiratory protection; eye protection; hand tools; power equipment; proper
ventilation; and the handling, storage, and disposal of chemicals/materials in
accordance with local, state, and federal safety and environmental regulations.
| I. STRUCTURAL ANALYSIS AND DAMAGE REPAIR |
|
A. Frame Inspection and Repair |
|
| 1. |
Diagnose and measure structural damage using tram and self-centering
gauges according to industry specifications. |
HP-I |
| 2. |
Attach frame anchoring devices. |
HP-I |
| 3. |
Straighten and align mash (collapse) damage. |
HP-G |
| 4. |
Straighten and align sag damage. |
HP-G |
| 5. |
Straighten and align sidesway damage. |
HP-G |
| 6. |
Straighten and align twist damage. |
HP-G |
| 7. |
Straighten and align diamond frame damage. |
HP-G |
| 8. |
Remove and replace damaged frame horns, side rails, and cross members
according to manufacturer's specifications/procedures. |
HP-G |
| 9. |
Restore corrosion protection to repaired or replaced frame areas. |
HP-G |
| 10. |
Repair or replace weakened or cracked frame members in accordance with
vehicle manufacturer's specifications/procedures. |
HP-G |
| 11. |
Identify misaligned or damaged steering, suspension, and powertrain
components that can cause vibration, steering, and wheel alignment problems;
align or replace in accordance with vehicle manufacturer's
specifications/procedures. |
HP-G |
| 12. |
Identify heat limitations in frame repair. |
HP-G |
| I. STRUCTURAL ANALYSIS AND DAMAGE REPAIR |
|
B. Unibody Inspection, Measurement, and Repair
INSTRUCTOR NOTE: For all the following tasks, recognize that measuring,
dimensioning, and tolerance limits in unibody vehicles are critical to repair of
these vehicles; recognize that suspension/steering mounting points and engine
power train attaching points are critical to vehicle safety, handling, and
performance.
|
|
| 1. |
Identify misaligned or damaged steering, suspension, and powertrain
components that can cause vibration, steering, and 4-wheel alignment problems;
realign or replace in accordance with vehicle manufacturer's
specifications/procedures. |
HP-G |
| 2. |
Diagnose and analyze unibody vehicle dimensions using a tram gauge. |
HP-I |
| 3. |
Determine and inspect the locations of all suspension, steering, and powertrain
component attaching points on the body. |
HP-G |
| 4. |
Diagnose and measure unibody vehicles using a dedicated (fixture) measuring
system. |
HP-G |
| 5. |
Diagnose and measure unibody vehicles using a universal measuring system
(mechanical, electronic, laser). |
HP-G |
| 6. |
Determine the extent of the direct and indirect damage and the direction of
impact; plan the methods and sequence of repair. |
HP-I |
| 7. |
Attach body anchoring devices; remove or reposition components as necessary. |
HP-I |
| 8. |
Straighten and align cowl assembly. |
HP-G |
| 9. |
Straighten and align roof rails/headers and roof panels. |
HP-G |
| 10. |
Straighten and align hinge and lock pillars. |
HP-G |
| 11. |
Straighten and align body openings, floor pans, and rocker panels. |
HP-G |
| 12. |
Straighten and align quarter panels, wheelhouse assemblies, and rear body
sections (including rails and suspension/powertrain mounting points). |
HP-G |
| 13. |
Straighten and align front-end sections (aprons, strut towers, upper and lower
rails, steering, and suspension/power train mounting points, etc.). |
HP-G |
| 14. |
Use proper heat stress relief methods in high strength steel in accordance with
manufacturer specifications/procedures. |
HP-G |
| 15. |
Use proper cold stress relief methods. |
HP-G |
| 16. |
Remove creases and dents using power tools and hand tools to restore damaged
areas to proper contours and dimensions. |
HP-I |
| 17. |
Determine the extent of damage to structural steel body panels; repair or replace. |
HP-I |
| 18. |
Remove and replace damaged sections of structural steel body panels in
accordance with manufacturer's specifications/ procedures. |
HP-G |
| 19. |
Restore corrosion protection to repaired or replaced unibody structural areas. |
HP-G |
| I. STRUCTURAL ANALYSIS AND DAMAGE REPAIR |
|
C. Fixed Glass |
|
| 1. |
Remove and replace fixed glass (heated and non-heated) using manufacturer's
specifications/procedures and recommended materials. |
HP-G |
| 2. |
Remove and replace modular glass using manufacturer's
specifications/procedures and recommended materials. |
HP-G |
| I. STRUCTURAL ANALYSIS AND DAMAGE REPAIR |
|
D. Metal Welding and Cutting |
|
| 1. |
Identify weldable and non-weldable materials used in collision repair. |
HP-I |
| 2. |
Weld and cut high-strength steel and other metals using manufacturer's
specifications/procedures. |
HP-I |
| 3. |
Determine the correct welder type, electrode, wire type, diameter, and gas to be
used in a specific welding situation. |
HP-I |
| 4. |
Set up welding equipment. |
HP-I |
| 5. |
Adjust the welder to "tune" for proper electrode stickout, voltage, polarity, flow
rate, and wire-feed speed required for the material being welded. |
HP-I |
| 6. |
Store, handle, and install high-pressure gas cylinders. |
HP-I |
| 7. |
Determine work clamp (ground) location and attach. |
HP-I |
| 8. |
Use the proper angle of the gun to the joint and direction of gun travel for the
type of weld being made in the flat, horizontal, vertical, and overhead positions. |
HP-I |
| 9. |
Protect adjacent panels, glass, vehicle interior, etc. from welding and cutting
operations. |
HP-G |
| 10. |
Protect computers and other electronic control modules during welding
procedures according to manufacturer's specifications.
|
HP-G |
| 11. |
Clean and prepare the metal to be welded, assure good metal fit-up, apply weld-
through primer if necessary, and clamp as required. |
HP-I |
| 12. |
Determine the joint type (butt weld with backing, lap, etc.) for weld being made
according to manufacturer's/industry specifications. |
HP-I |
| 13. |
Determine the type of weld (continuous, butt weld with backing, plug, etc.) for
each specific welding operation according to manufacturer's/industry
specifications. |
HP-I |
| 14. |
Perform the following welds: continuous, stitch, tack, plug, butt weld with
backing, and lap joints. |
HP-I |
| 15. |
Perform destructive tests on each weld type. |
HP-I |
| 16. |
Identify the causes of spits and sputters, burn through, lack of penetration,
porosity, incomplete fusion, excessive spatter, distortion, and waviness of bead;
make necessary adjustments. |
HP-I |
| 17. |
Identify cause of contact tip burn-back and failure of wire to feed; make
necessary adjustments. |
HP-I |
| 18. |
Identify cutting process for different materials and locations in accordance with
manufacturer's procedures; perform cutting operation. |
HP-G |
