Auto Body Repairs

Safety rules and regulations in Auto body repairs and

spray painting.

1.2.     List of rules and regulations and their importance.

1.3      List of safety tools and equipment/machines for auto body repairs.

1.4       Auto body dressing code:             personal protective equipment             (nose mask, goggles, boots,             ear defender, etc).

1.5     Sources of accident (human factors, machinery/equipment and workshop keeping)             and their preventions.

1.6     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).

1:3:1   Identification of safety tools and equipment and demonstration of              their usage.

1:4:1   Identification of                       dress code and                       protective                       equipment and                       demonstration of

their usage.

1:5:1 Identification of containers for hazardous waste.

1:5:2  Demonstration of horseplay.

1:5:3   Report faulty               machines/

equipment

1:5:4    Demonstration of              workshop keeping             e.g. cleaning oil             and water from             the floor with sawdust and dry sand

(a)    Basic Hand Tools

(b)    Spray painting tools          and equipment.

(c)    Care and maintenance of tools and equipment.

2.1    Types of hand tools. (hammers,          dollies, spanners, files,          ratchets, body spoons, etc) and          their uses.

2.2    Types and Uses of power tools

and  equipment/machines (drilling

machine, body jack, sanders,           air compressor, shaping machines, cutting machines, etc).

2.3    Advantages and disadvantages          of machines.

2.4   Uses of Machines and safety precautions.

2.5   Spray painting tools and          equipment (scrapers, brushes,          funnels, paint pots, spray gun, spray body filters, air compressor,          oven, spray boot, etc).

2.6     Definition of maintenance and types – predictive, preventive and corrective.

2.7     Manufacturer’s maintenance guide.

2.8     Maintenance of tools and                equipment.

2:1:1    Identification of             hand tools and             equipment

2:2:1   Identification and demonstration of the use of              power tools.

2:4:1   Demonstration of the use of the machine.

2:5:1   identification of spray painting tools,            equipment and their uses.

2:8:1   Dismantling and            assembly of a            spray gun

2:8:2   Cleaning of  tools

and equipment

(a)    Auto-body Repairs materials.

(b)     Spray painting

materials.

–  plastic filler;

– fibreglass fillers;

– body solder; 30/70 and 40/60.

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

Sanding disc.

3.3     Type of sealers e.g. rubber

sealers, seam sealers,           undercoating, etc.

3.4.     Rivet pins e.g. pop and            solid rivets.

3.5      Types of paints – Enamel paints and lacquers.

– Undercoats: surface primer,          putty/body filler, sealers.

–     Top coats:  lacquers and enamel        paints.

3.6    Manufactures paint guide: paint          formula, paint mixing equipment,          custom-mix base colours, paint labels, color charts.

3:2:1   Identification of body abrasives.

.

3:4:1   Demonstration of the use of rivet gun.

3:5:1   Identification of

paints by use of                thinner.

3:5:2   Demonstration of the use of undercoats.

3:5:3    Demonstration of those of top coats.

3:6:1  Demonstration of           how to mix paints

3:6:2   Identification of                       colours using colour            chats

4.2    Properties of metals – fusibility,

malleability, ductility, weldability,          etc.

4.3    Uses of metals on Auto bodies.

4:1:2   Demonstration of properties of metals.

5.2    Types and process of heat treatment e.g. hardening,           annealing, normalizing, case-          hardening and tempering.

5.3    Importance of heat treatment.

5:2:1   Demonstration of heat treatment processes.

6.2    Safety precautions

6.3    Oxy-acetylene welding          equipment.

6.4    Types of oxy-acetylene gas used          e.g.(high and low-pressure systems).

6.5    Installations of welding          equipment.

6.6    Welding nozzles.

6.7    Defects of oxy-acetylene welding           – slag inclusion, porosity, crack,           lack of penetration, etc and their remedies.

6:3:1   Identification of equipment.

6:4:1  Demonstration of how to use the high and low-pressure system.

6:5:1  Demonstration of how to assemble welding equipment.

6:6:1  Demonstration of how to install welding equipment.

6:7:1   Identification of weld defects.

(a)    Minor auto body repair.

(b)    Major auto body repair.

(i)  integral body;

(ii)  composite body .

7.2    Basic methods of straightening the auto body:  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.

7.3     Tools used in-minor repairs-           hammers, hand dollies, spoons,           spanners, screwdrivers, etc.

7.4     Major body sections e.g. front           engine compartment,           passenger section, rear section

7.5    Basic alignment principle.

7.6    Quarter panel cutting.

7.7 Lightweight panels.

7.8     Damaged vehicle alignment.

7:2:1   Identification of auto-body repair tools.

7:2:2   Identification of heat-shrinking tools.

7:3:1    Demonstration of              how to use the              tools in carrying              out minor repairs.

7:4:1    Identification of major body sections.

7:6:1   Identification of quarter panel and demonstration of how to cut it.

7:7:1   Repair and aligning of body sections.

8.2    Repair and alignment of          damaged aluminum panel.

8.3    Aluminum deck lid repair.

8:3:1   Aluminum deck lid            repair procedure

9.2    Types of plastic resins            (thermosetting and thermoplastic).

9.3    Repair of plastic parts by melting.

9.4    Introduction to glass fibre panel repair.

9:2:1   Identification of plastics.

9:3:1   Demonstration of              how to repair plastic parts by melting.

(a)    Spray gun and          accessories.

(b)    Surface preparation.

(c)     Type of paints.

(d)   Metallic paint.

10.1    Spray gun – pressure feed gun siphon and the gravity gun.

10.2     Spray gun parts – air cap, fluid needle, air valve, trigger gun,             body, cup, etc.

10.3     Precautions in the use of spray guns.

10.4    Manufacturer’s maintenance guide.

10.5    Preparation of surfaces for spray painting.

10.6    Paints used on auto bodies cellulose synthetic paint, enamel paint, acrylic, metallic paints,            etc.

10.7    Importance of manufacturer’s paint code.

10.8    Special paints and their importance.

10.9    Variable agents (flakes and pigments).

10.10   Metallic spray techniques (wet and dry spray).

10:1:1   Identification of pressure feed gun, siphon gun and the gravity gun.

10:5:1   Preparation of              metal surfaces for              spray painting.

10:6:1   Identification of paints used on auto bodies.

10:10:1   Demonstration

of metallic                 spray techniques.

11.2    List of tools and equipment.