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Auto Body Repair Technology Fifth Edition This page intentionally left blank Auto Body Repair Technology Fifth Edition James E. Duffy Australia Brazil Canada Mexico Singapore Spain United Kingdom United States Auto Body Repair Technology © 2009 Delmar Cengage Learning Fifth Edition ALL RIGHTS RESERVED.No part of this work covered by the James E.Duffy copyright herein may be reproduced,transmitted,stored or used in any form or by any means graphic,electronic,or mechanical, Vice President,Technology including but not limited to photocopying,recording,scanning, and Trades ABU: David Garza digitizing,taping,Web distribution,information networks,or Director of Learning Solutions: Sandy information storage and retrieval systems,except as permitted Clark under Section 107 or 108 of the 1976 United States Copyright Managing Editor: Larry Main Act,without the prior written permission of the publisher. Executive Editor: David Boelio Senior Product Manager: Matthew Thouin For product information and technology assistance,contact us Marketing Director: Deborah S.Yarnell at Cengage Learning Academic Resource Center, Senior Marketing Manager: Erin Coffin 1-800-423-0563 Marketing Coordinator: Patti Garrison For permission to use material from this text or product,submit all requests online at www.cengage.com/permissions Director of Production: Patty Stephan Further permissions questions can be emailed to Content Project Manager: Barbara L.Diaz [email protected] Content Project Manager: Cheri Plasse Editorial Assistant: Lauren Stone Library of Congress Cataloging-in-Publication Data Cover image: Courtesy of Ford Motor Duffy,James E. Company Auto body repair technology/James E.Duffy.– 5th ed. p.cm. ISBN 1-4180-7353-9 1. Motor vehicles--Bodies--Maintenance and repair. I. Title. TL255.D86 2007 629.2'60288--dc22 2007042899 ISBN-10:1-4180-7353-9 ISBN-13:9781418073534 Notice to the Reader Publisher does not warrant or guarantee any ofthe products described herein or perform any independent analysis in connection withany ofthe product information contained herein.Publisher does not assume,and expressly disclaims,any obligation to obtain andinclude information other than that provided to it by the manufacturer.The reader is expressly warned to consider and adopt all safety precautions that might be indicated by the activities herein and to avoidall potential hazards.By following the instructions contained herein,the reader willingly assumes all risks in connection with suchinstructions.The publisher makes no representation or warranties ofany kind,including but not limited to,the warranties offitness for particular purpose or merchantability,nor are any such representations implied with respect to the material set forth herein, and the publisher takes no responsibility with respect to such material.The publisher shall not be liable for any special,consequential,or exemplary damages resulting,in whole or part,from the readers’use of,or reliance upon,this material. Printed in the United States of America 1 2 3 4 5 XX 08 07 06 Contents PREFACE xi Chapter4 HAND TOOL TECHNOLOGY 89 ACKNOWLEDGMENTS xiii 4.1 General Purpose Tools 89 FEATURES OF THE TEXT xv 4.2 Bodyworking Tools 106 4.3 Body Surfacing Tools 115 4.4 Hand Tool Safety 118 SECTION I Review Questions 120 INTRODUCTION Chapter5 Chapter 1 POWER TOOL AND EQUIPMENT COLLISION REPAIR: TECHNOLOGY 122 INTRODUCTION AND CAREERS 3 5.1 Air-Powered Tools 122 1.1 What Is Collision Repair? 3 5.2 Electric-Powered Tools 140 1.2 Body Shop Repairs 6 5.3 Hydraulically Powered Shop 1.3 Auto Body Careers 17 Equipment 148 Review Questions 20 5.4 Power Jacks and Straightening Equipment 148 5.5 Hydraulic Tool Care 151 Chapter 2 5.6 Hydraulic Lifts 151 VEHICLE CONSTRUCTION Review Questions 155 TECHNOLOGY 22 2.1 Body and Chassis 22 Chapter 6 2.2 Vehicle Frame 23 COMPRESSED AIR SYSTEM 2.3 Major Body Sections 24 TECHNOLOGY 157 2.4 Body Classifications 26 2.5 Auto Body Repair History 29 6.1 The Air Compressor 158 2.6 Unibody Panels 32 6.2 Air and Fluid Control 2.7 Unibody Design Factors 36 Equipment 162 2.8 Body-Over-Frame Considerations 45 6.3 Compressor Accessories 167 2.9 Crash Testing 47 6.4 Air System Maintenance 169 Review Questions 51 6.5 Air System Safety 170 Review Questions 172 Chapter3 SERVICE INFORMATION, Chapter7 SPECIFICATIONS, AND BODY SHOP MATERIALS MEASUREMENTS 54 AND FASTENER TECHNOLOGY 174 3.1 Service Information 55 3.2 Vehicle Identification 63 7.1 Refinishing Materials 174 3.3 Using Service Information 64 7.2 Fasteners 194 3.4 Collision Repair Measurements 69 Review Questions 203 Review Questions 87 v vi Contents Chapter8 11.2 Classifying Body Damage 327 11.3 Analyzing Sheet Metal Damage 327 WELDING EQUIPMENT 11.4 Metal Straightening Techniques 329 TECHNOLOGY 205 11.5 Metal Shrinking, Stress Relieving 341 8.1 MIG Welding 211 11.6 Working Aluminum Panels 345 8.2 MIG Welding Equipment 214 11.7 Paintless Dent Removal 346 8.3 MIG Operation Methods 217 Review Questions 349 8.4 Basic Welding Techniques 224 8.5 MIG Welding Galvanized Metals and Chapter12 Aluminum 232 8.6 Testing the MIG Weld 234 USING BODY FILLERS 351 8.7 MIG Weld Defects 234 12.1 Body Fillers 352 8.8 Flux-Cored Arc Welding 234 12.2 Applying Body Filler 355 8.9 TIG Welding 237 12.3 Grating and Sanding Body Filler 363 8.10 Resistance Spot Welding 237 12.4 Repairing Paint Surface Imperfections 372 8.11 Other Spot Welding Functions 246 12.5 Repairing Rust Damage 375 8.12 Stud Spot Welding for Dent Removal 246 Review Questions 382 8.13 Oxyacetylene Welding 246 8.14 Brazing 252 8.15 Soldering (Soft Brazing) 255 Chapter13 8.16 Plasma Arc Cutting 256 REPAIRING PLASTICS 385 Review Questions 260 13.1 Types of Plastics 385 13.2 Plastic Repair 387 Chapter 9 13.3 Chemical-Adhesive Bonding SHOP SAFETY AND EFFICIENCY 262 Techniques 392 13.4 Plastic Welding 394 9.1 Shop Accidents 263 13.5 Hot-Air Plastic Welding 394 9.2 Personal Safety 265 13.6 Airless Plastic Welding 397 9.3 General Shop Safety Procedures 274 13.7 Ultrasonic Plastic Welding 397 9.4 Tool and Equipment Safety 276 13.8 Plastic Welding Procedures 397 9.5 Fire Safety 280 13.9 Repairing Vinyl 400 9.6 Hazardous Material Safety 283 13.10 Ultrasonic Stud Welding 401 9.7 Good Shop Housekeeping 286 13.11 Reinforced Plastic Repair 401 9.8 Air Bag Safety 287 Review Questions 409 Review Questions 289 Chapter14 SECTION II HOOD, BUMPER, FENDER, LID, ESTIMATING AND TRIM SERVICE 411 14.1 How Are Fastened Parts Chapter10 Serviced? 412 14.2 Hood Service 413 ESTIMATING REPAIR COSTS 293 14.3 Bumper Service 419 10.1 The Estimate 293 14.4 Fender Service 422 10.2 Part Prices 296 14.5 Grille Service 424 10.3 Labor Costs 300 14.6 Deck Lid and Hatch Service 424 10.4 Refinishing Time 301 14.7 Truck Bed Service 426 10.5 Estimate Total 303 14.8 Sound-Deadening Pads 427 10.6 Computer Estimating 303 14.9 Custom Body Panels 427 10.7 Computer Database 306 14.10 Installing Body Trim and Moldings 428 10.8 Estimating Sequence 309 Review Questions 433 10.9 Vehicle Total Loss 315 Review Questions 318 Chapter15 DOOR, ROOF, AND GLASS SECTION III SERVICE 435 MINOR REPAIRS 15.1 Vehicle Glass Technology 435 15.2 Glass Service 436 Chapter11 15.3 Servicing Doors 446 15.4 Door Panel (Skin) Replacement 453 WORKING SHEET METAL 323 15.5 Panel Adhesive Technology 456 11.1 Automotive Sheet Metal 324 15.6 Door and Door Glass Adjustments 456 Contents vii 15.7 Door Glass Service 459 Chapter 19 15.8 Rearview Mirror Service 463 WELDED PANEL REPLACEMENT 579 15.9 Roof Panel Service 464 19.1 Welded Panels 579 Review Questions 465 19.2 Removing Structural Panels 583 19.3 Preparing Panels for Welding 587 Chapter 16 19.4 Structural Sectioning 595 PASSENGER COMPARTMENT 19.5 Sectioning Side Members (Frame Rails) 608 SERVICE 467 19.6 Rear Impact Damage Repair 614 19.7 Antirust Treatments 616 16.1 Passenger Compartment Assemblies 467 19.8 Replacing Panels with Adhesives 616 16.2 Interior Trim 469 Review Questions 618 16.3 Roll Bars 470 16.4 Seat Service 470 16.5 Carpeting Service 472 Chapter20 16.6 Dash Panel Service 474 RESTORING CORROSION 16.7 Console Service 476 PROTECTION 620 16.8 Instrument Cluster Service 478 16.9 Headliner Service 478 20.1 What Is Corrosion? 620 16.10 Locating Air and Water Leaks 479 20.2 Causes for Loss of Factory 16.11 Rattle Elimination 484 Protection 623 20.3 Anticorrosion Materials 625 Review Questions 486 20.4 Basic Surface Preparation 627 20.5 Corrosion Treatment Areas 631 SECTION IV 20.6 Corrosion-Protection Primers 631 20.7 Exposed Joints 633 MAJOR BODY/FRAME REPAIRS 20.8 Exposed Interior Surfaces 636 20.9 Exposed Exterior Surfaces 637 Chapter17 20.10 Exterior Accessories 638 20.11 Acid Rain Damage 638 BODY/FRAME DAMAGE MEASUREMENT 491 Review Questions 640 17.1 Impact and Its Effects on a Vehicle 493 17.2 Visually Determining the Extent of SECTION V Impact Damage 501 MECHANICAL AND 17.3 Measurement of Body Dimensions 502 17.4 Gauge Measuring Systems 503 ELECTRICAL REPAIRS 17.5 Tram Gauges 503 17.6 Digital Tram Gauges 509 Chapter21 17.7 Centering Gauges 512 CHASSIS SERVICE AND WHEEL 17.8 Diagnosing Damage Using Gauge Measuring Systems 515 ALIGNMENT 645 17.9 Strut Centerline Gauge 518 21.1 Powertrain Construction 646 17.10 Universal Measuring Systems 519 21.2 Suspension and Steering 17.11 Computerized Measuring Systems 657 Systems 522 21.3 Wheel Alignment 669 Review Questions 540 21.4 Brake Systems 677 21.5 Cooling Systems 682 Chapter18 21.6 Heater Operation 687 21.7 Air-Conditioning Systems 688 UNIBODY/FRAME 21.8 Exhaust Systems 696 REALIGNMENT 542 21.9 Emission Control Systems 700 18.1 Realignment Basics 543 21.10 Hose and Tubing Inspection 702 18.2 Unibody/Frame Straightening 21.11 Fuel System Service 703 Equipment 549 Review Questions 705 18.3 Straightening and Realigning Techniques 556 Chapter22 18.4 Measuring When Pulling 559 ELECTRICAL/ELECTRONIC 18.5 Planning the Pull 563 18.6 Making Pulls 565 SYSTEM OPERATION AND 18.7 Executing a Pulling Sequence 565 SERVICE 708 18.8 Stress Relieving 572 22.1 Electrical Terminology 708 Review Questions 575 22.2 Checking Electrical Problems 714 viii Contents 22.3 Battery 716 Chapter26 22.4 Electrical Diagnostic Equipment 718 REFINISHING PROCEDURES 865 22.5 Electric Components 722 22.6 Circuit Protective Devices 723 26.1 Purpose of Refinishing 866 22.7 Lighting and Other Electrical Circuits 728 26.2 Topcoats 866 22.8 Electronic System Service 736 26.3 Primecoats 869 22.9 Electronic Displays 736 26.4 Preparing Refinish Materials 870 22.10 Computer Systems 737 26.5 Prepainting Preparations 878 26.6 Applying Primecoats 882 Review Questions 744 26.7 Refinishing Plastic Parts 883 26.8 Flash Times 885 Chapter23 26.9 Basic Spray Coats 886 26.10 Methods of Refinishing 891 RESTRAINT SYSTEM OPERATION 26.11 Basecoat/Clearcoat Repairs 892 AND SERVICE 746 26.12 Applying Single Stage Paints 898 23.1 Seat Belt Systems 746 26.13 Panel Repairs 898 23.2 Seat Belt Service 749 26.14 Overall Refinishing 899 23.3 Air Bag System Operation 751 26.15 Removal of Masking Materials 900 23.4 Servicing Air Bag Systems 759 Review Questions 903 23.5 Roll Bar Service 765 Review Questions 767 Chapter27 COLOR MATCHING AND CUSTOM PAINTING 905 SECTION VI 27.1 Color Theory 906 REFINISHING 27.2 Using a Paint Color Directory 908 27.3 Matching Basic Paint Colors 910 27.4 Matching Basecoat/Clearcoat Finishes 915 Chapter24 27.5 Matching Three-Stage Paints 915 REFINISHING EQUIPMENT 27.6 Tinting 920 TECHNOLOGY 771 27.7 Custom Painting 927 Review Questions 932 24.1 Spray Guns 772 24.2 Equipment and Material Preparation 780 Chapter28 24.3 Spray Gun Setup 783 PAINT PROBLEMS AND FINAL 24.4 Using a Spray Gun 788 DETAILING 934 24.5 Spray Gun Maintenance 792 24.6 Spray Gun Troubleshooting 796 28.1 Repairing Paint Problems 934 24.7 Other Spray Systems 797 28.2 Masking Problems 947 24.8 Spray Booths 805 28.3 Final Detailing 947 24.9 Spray Booth Maintenance 810 28.4 Paint Compounding 952 24.10 Drying Room 813 28.5 Final Cleaning 958 24.11 Air-Supplied Respirators 815 28.6 Caring for a New Finish 959 24.12 Other Paint Shop Equipment Review Questions 960 and Tools 816 Review Questions 821 SECTION VII COLLISION REPAIR Chapter25 PROFESSIONALISM VEHICLE SURFACE PREPARATION AND MASKING 824 Chapter29 25.1 Evaluate Surface Condition 824 JOB SUCCESS AND ASE 25.2 Paint Removal 826 CERTIFICATION 965 25.3 Preparing Bare Metal 829 25.4 Primecoat Selection 832 29.1 Career Goals 965 25.5 Final Sanding 837 29.2 Worker Traits 966 25.6 Masking 844 29.3 Entrepreneurship 967 25.7 Surface Cleaning 859 29.4 Certification Programs 968 Review Questions 862 Review Questions 971 Contents ix Appendix A AppendixC AUTO BODY SHOP TERMS DECIMAL AND METRIC TÉRMINOS DEL TALLER DE EQUIVALENTS 1013 CARROCERÍA 973 AppendixD AppendixB VISCOSITY CONVERSION ABBREVIATIONS USED BY BODY CHART 1014 TECHNICIANS AND ESTIMATORS 1011 INDEX 1015