Auto Body Repairs Waec Syllabus

Safety rules and regulations in Auto body repairs and spray painting.

1. Definition of safety rules and regulations in auto body repairs and spray painting.
2. List of rules and regulations and their importance.
3. List of safety tools and equipment/machines for auto body repairs
4. Auto body dressing code: personal protective equipment             (nose mask, goggles, boots, ear defender, etc)
5. Sources of accident (human factors, machinery/equipment and workshop keeping) and their preventions.
6. Factory acts on safety rules and regulations: 1984 amended resource conservation recovery act, environmental protection agency regulations and hazardous waste collection and recycling (solvent recovery system).

Tools and Equipment

1. Basic Hand Tools
   • Types of hand tools. (hammers, dollies, spanners, files, ratchets, body spoons, etc.) and their uses.
   • Types and Uses of power tools and  equipment/machines (drilling machine, body jack, sanders, air compressor, shaping machines, cutting machines, etc).
   • Advantages and disadvantages of machines.
   • Uses of Machines and safety precautions.
2. Spray painting tools          and equipment.
   • Spray painting tools and equipment (scrapers, brushes, funnels, paint pots, spray guns, spray body filters, air compressors, ovens, spray boots, etc.).
3. Care and maintenance of tools and equipment.
   • Definition of maintenance and types: predictive, preventive, and corrective.
   • Manufacturer’s maintenance guide.
   • Maintenance of tools and equipment.

Materials for auto-body repairs and spray painting

1. Auto-body Repairs materials.

   Types of Body Fillers

   • plastic filler;
   • fibreglass fillers;
   • body solder; 30/70 and 40/6

   Type of body abrasives e.g. sandpapers, (wet and dry); Sanding disc.

   Type of sealers e.g. rubber sealers, seam sealers, undercoating, etc.

   Rivet pins e.g. pop and  solid rivets.

2. Spray painting materials.
   • Types of paints – Enamel paints and lacquers.
   • Undercoats: surface primer, putty/body filler, sealers.
   • Top coats:  lacquers and enamel paints.
   • Manufactures paint guide: paint formula, paint mixing equipment, custom-mix base colours, paint labels, color charts.

Type of metals.

1. Ferrous and non ferrous metals mild steel, cast iron, aluminum, brass, etc.
2. Properties of metals – fusibility, malleability, ductility, weldability, etc.
3. Uses of metals on Auto bodies

Heat treatment of metals

1. Definition of heat treatment
2. Types and process of heat treatment e.g. hardening,           annealing, normalizing, case-hardening and tempering.
3. Importance of heat treatment

Oxy-acetylene welding and equipment.

1. Definition of oxy-acetylene welding.
2. Safety precautions
3. Oxy-acetylene welding equipment.
4. Types of oxy-acetylene gas used e.g.(high and low-pressure systems).
5. Installations of welding          equipment.
6. Welding nozzles
7. Defects of oxy-acetylene welding – slag inclusion, porosity, crack,           lack of penetration, etc and their remedies

Auto body repair work

1. Minor auto body repair.

   Types of auto body

   • integral body;
   • composite body.

   Basic methods of straightening the auto body include aligning the metal with a power jack, pulling the metal with a sledgehammer, using a pre-bar, and pulling the metal with pull taps. Heat-shrinking the metal to  bring the metal back to its original shape.

2. Major auto body repair
   • Tools used in-minor repairs: hammers, hand dollies, spoons, spanners, screwdrivers, etc.
   • Major body sections e.g. front engine compartment, passenger section, rear section
   • Basic alignment principle
   • Quarter panel cutting.
   • Lightweight panels.
   • Damaged vehicle alignment.

Aluminum panel repair

1. Steps Involved in aluminum panel repair
2. Repair and alignment of damaged aluminum panel
3. Aluminum deck lid repair

Plastic repairs

1. Precautions while working with plastics
2. Types of plastic resins (thermosetting and thermoplastic)
3. Repair of plastic parts by melting
4. Introduction to glass fibre panel repair

Spray painting

1. Spray gun and accessories
   • Spray gun – pressure feed gun siphon and the gravity gun.
   • Spray gun parts – air cap, fluid needle, air valve, trigger gun, body, cup, etc.
   • Precautions in the use of spray guns.
   • Manufacturer’s maintenance guide.
2. Surface preparation
   • Preparation of surfaces for spray painting.
3. Type of paints.
   • Paints used on auto bodies cellulose synthetic paint, enamel paint, acrylic, metallic paints, etc.
   • Importance of manufacturer’s paint code.
   • Special paints and their importance.
   • Variable agents (flakes and pigments)
4. Metallic paint
   • Metallic spray techniques (wet and dry spray).

Auto body workshop business

1. Factors to consider in locating an auto body repair shop – capital, accessibility, land, etc
2. List of tools and equipment

RECOMMENDED READING LIST

1. RECOMMENDED READING LIST
2. Fundamentals of vehicle bodywork by J. Fairbrother.
3. Practical welding (The motivate series Mac-Milan texts for Industrial Vocational and Technical Education) by S. Gibson.
4. Fundamentals of motor vehicle technology, chassis and body electronics (5th Edition) Book 1, 2, and 3 by Hilliers V. A. W. and David R. Rogers.
5. Bodywork Maintenance and repair, including interiors, by Paul Browne.
6. Automotive encyclopedia by Good Heart-Willcox.
7. Auto body repair and repainting by Bill Tobold.