Eastfield College Career Technologies Course Syllabus for ABDR 1555.4001 Minor Metal 5hrs Spring 2012 Class room T-010Eastfield College Career Technologies Division ABDR1555.4001 / 4501 MINOR METAL REPAIR Spring 2012 MONDAY- WEDNESDAY AM 8-12:00 (.4001) INSTRUCTOR: Stephanie Graham OFFICE: T149 TELEPHONE: 972 860 7252 Fax: 972 860 8393 EMAIL [email protected] Office hours: MW12:15pm – 1:15pm TR 4:30pm – 5:30pm F 12:55pm-1:55pm MINOR METAL REPAIR COURSE DESCRIPTION (5) This is a WECM course number. Course Description: Prerequisite NONE Sheet metal alignment principles using mechanical and hydraulic equipment. Emphasis on attachment devices used to straighten and align exterior body panels (3 LEC , 6 LAB) REQUIRED TEXT AND LAB KIT Textbook: Auto Body Repair Technology 5th Edition ISBN (0-7668-6272-0) Lab kit: a lab kit is required. Kits consist of: Approved respirator, mixing board, spreader rubber gloves, sanding block squeegee safety glasses mixing knife, cheese grater file, and sanding sponge. School ID is required Major tools are furnished by the program and checked out of the tool room as necessary This syllabus is subject to change for the benefit of the educational process for the students.SAFETY IS A MAJOR PART OF THIS PROGRAM. SAFETY GLASSES MUST BE WORN AT ALL TIMES IN LABS. Students that do not comply will be asked to leave the shop. Safety is a part of your daily grade. All Students must assist in cleaning the shop for safety reasons to prevent falls and accidents. Roll will be taken only after the shop is cleaned. Shop Attire For the safety of all students we ask that students not wear loose, frayed, or baggy clothing. If pants are too loose please wear a belt. Baggy clothing can be caught in grinders and buffers. Frayed clothing can be easily caught on fire. INTELLECTUAL COMPETENCIES: Scans Workplace Competencies Scans Foundations (1a) (1c) (1d) (6a) (6b) (6c) (6d) (6e) (2a) (2b) (2c) (2d) (2e) (2f) (7a) (7b) (7c) (7d) (7e) (3a) (3b) (3c) (3d) (8a) (8b) (8c) (8d) (8e) (4a) (4b) (4c) (4d) (5a) (5b) (5c) Visit http://wdr.doleta.gov/SCANS/ for more information on the Secretary's Commission on Achieving Necessary Skills EDUCATIONAL OBJECTIVES: Upon successful completion of this course, the student will: Know Sheet metal alignment principles using mechanical and hydraulic equipment. Emphasis on attachment devices used to straighten and align exterior body panels Student Learning Outcomes (SLO’S): Students are expected to properly disassemble and reassemble car panels as well as properly set up equipment to pull panels on a car. Students are expected to be able to properly use power tools for auto body repair safely. NATEF TASK LIST NON-STRUCTURAL ANALYSIS AND DAMAGE REPAIR (BODY COMPONENTS) For every task in Non-Structural Analysis and Damage Repair (Body Components), 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. II. NON-STRUCTURAL ANALYSIS AND DAMAGE REPAIR (BODY COMPONENTS)A. Preparation 1. Review damage report and analyze damage to determine appropriate methods for overall repair; develop and document a repair plan. HP-I 2. Inspect, remove, store, and replace exterior trim and moldings. HP-I 3. Inspect, remove, store, and replace interior trim and components. HP-I 4. Inspect, remove, store, and replace non-structural body panels and components that may interfere with or be damaged during repair. HP-I 5. Inspect, remove, store, and replace all vehicle mechanical and electrical components that may interfere with or be damaged during repair. HP-G 6. Protect panels, glass, and parts adjacent to the repair area. HP-I 7. Soap and water wash entire vehicle; use appropriate cleaner to remove contaminants from those areas to be repaired. HP-I 8. Remove corrosion protection, undercoatings, sealers, and other protective coatings necessary to perform repairs. HP-I 9. Inspect, remove, and replace repairable plastics and other components that are recommended for off-vehicle repair. HP-G 10. Apply safety procedures associated with vehicle components and systems according to manufacturers specifications/procedures. HP-G 11. Apply environmental practices associated with vehicle components and systems such as substrates, fluids, refrigerants, batteries, etc. HP-I II. NON-STRUCTURAL ANALYSIS AND DAMAGE REPAIR (BODY COMPONENTS) B. Outer Body Panel Repairs, Replacements, and Adjustments 1. Determine the extent of direct and indirect damage and direction of impact; develop and document a repair plan. HP-I 2. Inspect, remove and replace bolted, bonded, and welded steel panel or panel assemblies. HP-I 3. Determine the extent of damage to aluminum body panels; repair or replace in accordance with manufacturer’s specifications. HP-G 4. Inspect, remove, replace, and align hood, hood hinges, and hood latch. HP-I 5. Inspect, remove, replace, and align deck lid, lid hinges, and lid latch. HP-I 6. Inspect, remove, replace, and align doors, tailgates, hatches, lift gates, latches, hinges, and related hardware. HP-I 7. Inspect, remove, replace, and align bumper bars, covers, reinforcement, guards, isolators, and mounting hardware. HP-I 8. Inspect, remove, replace and align front fenders, headers, and other panels. HP-I 9. Straighten and rough-out contours of damaged panels to a suitable condition for body filling or metal finishing using power tools, hand tools, and weld-on pull attachments. HP-I 10. Weld damaged or torn steel body panels; repair broken welds. HP-I 11. Restore corrosion protection. HP-I12. Replace door skins according to manufacturer’s procedures. HP-G 13. Restore sound deadeners and foam materials. HP-G 14. Perform panel bonding according to manufacturer’s specifications. HP-G 15. Diagnose and repair water leaks, dust leaks, and wind noise. HP-G II. NON-STRUCTURAL ANALYSIS AND DAMAGE REPAIR (BODY COMPONENTS) C. Metal Finishing and Body Filling 1. Remove paint from the damaged area of a body panel. HP-I 2. Locate and reduce surface irregularities on a damaged body panel. HP-I 3. Demonstrate hammer and dolly