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Eastfield College Career Technologies Course Syllabus ABDR 1555 Minor Metal 5hrs T137 Spring 2012 Eastfield College ABDR1555.4501 MINOR METAL REPAIR Spring 2012 MONDAY- WEDNSDAY PM 5:35-9:35 (.4501) INSTRUCTOR: Ford J. OFFICE: T149 TELEPHONE: 972 860 7143 Fax: 972 860 8393 EMAIL [email protected] 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 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 HP-G 44 according to manufacturers specifications/procedures.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-I 12. 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 45 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 techniques. HP-I 4. Heat shrink stretched panel areas to proper contour according to manufacturer’s specifications. HP-G 5. Cold shrink stretched panel areas to proper contour. HP-G 6. Mix body filler. HP-I 7. Apply body filler; shape during curing. HP-I 8. Rough sand cured body filler to contour; finish sand. HP-I II. NON-STRUCTURAL ANALYSIS AND DAMAGE REPAIR (BODY COMPONENTS) D. Moveable Glass and Hardware 1. Inspect, adjust, repair or replace window regulators, run channels, glass, power mechanisms, and related controls. HP-G 2. Diagnose and repair water leaks, dust leaks, and wind noises; inspect, repair, and replace weather-stripping. HP-G 3. Inspect, repair or replace, and adjust removable, manually or power operated roof panel and hinges, latches, guides, handles, retainer, and controls of sunroofs. HP-G 4. Inspect, remove, reinstall, and align convertible top and related mechanisms. HP-G II. NON-STRUCTURAL ANALYSIS AND DAMAGE REPAIR (BODY COMPONENTS) E. 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 steels using manufacturer’s specifications/procedures. HP-I 3. Weld and cut aluminum using manufacturer’s specifications/procedures. HP-G 464. Determine the correct welder type, electrode, wire type, diameter, and gas to be used in a specific welding situation. HP-I 5. Set up and adjust the GMAW (MIG) 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-I 10. Protect computers and other electronic control modules during welding procedures according to manufacturer’s specifications. HP-I


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DCCCD ABDR 1555 - Syllabus

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