GM Non-Structural Training Course 5 days

NON-STRUCTURAL BODY REPAIR - 5 DAYS
1

INTRODUCTIONINTRODUCTION
Presenter Background
(Enter summary of presenter skills and
work history)
Content for this slide will be entered
by the Trainer
22

GROUND RULES
Make sure all safety equipment discussed in the course are available for demonstration
Content for this slide will be entered by the Trainer
H E A L T H
A N D S A F E T Y
C O F F E E & L U N C H
B R E A K S
H E A L T H
A N D S A F E T Y
M O B I L E
P H O N E S
N O S M O K I N G
F I R E
P R E C A U T I O N S
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Upon completion of this course the
technician will gain underpinning
knowledge and practical experience of:
General characteristics of a
bodyshop
Automotive Bodies - HSS & Fe
composition (non-structural)
Health and Safety
Workshops Tools & Equipment
Panel Straightening & Dent Repair
Roughing Out Panels and
Feathering for Putty
Putty Application
COURSE GOAL
4

Technicians will:
Understand outer body construction
Understand how to work in a safe
environment
Have greater knowledge of bodyshop
tools and equipment
Understand how to repair dents using
several different methods
Be able to finish a dent repair to meet
an acceptable standard and
Know how to feather and apply putty
after a dent has been roughed out
COURSE OBJECTIVES
5

COURSE AGENDA
Lesson Lesson name Day
1 Health & Safety 1
2 Tools & Equipment 1
3 Metal Characteristics 2
4 Shrinking 2
5 Roughing Out Techniques 2
6 Dent Pulling 3
7 Body Filing & Metal Finishing 3
8 Introduction to Aluminium Repair 4
9 Body Filler Mixing & Application 4
10 Anti-Corrosion Sealing 4
Course Summary 5
Written & Practical Testing 5
6

7
LESSON 1
H E A LT H A N D S A F E T Y W I T H I N
A B O DY R E PA I R S H O P

If you see this sign means that it is a point to note!
KEY POINTS
8

Many people die each year at work and
several hundred lose time through
injury and illness
1000s of injuries each year are
reported; possibly many more are not
Injuries in bodyshop include; Eye injury,
cuts, burns, Repetitive Strain Injury (RSI)
More serious, long term, injuries
include; Respiratory illnesses, defective
nervous system and even Cancer
SAFETY IS EVERYONE’S CONCERN
9

What is an accident?
An unplanned event leading to harm
and/or damage, including near misses
ACCIDENT CAUSES
10

Unsafe Situation
Unsafe Act
Spotting these BEFORE they happen is key to good safety management
ACCIDENT CAUSES
11

Employees now have no hesitation in claiming for work related injuries and illnesses.
Areas in which they claim for include:
Vibration Syndrome, also called White Finger - Miners and people who use air tools
suffer from this lack of blood flow in the hands.
Occupational Asthma - can be caused by not using exhaust extraction in the workshop
and bodyshop technicians not using spray booths, breathing apparatus, etc.
Injury caused my poor Manual Handling, lifting and carrying etc.
Hearing Damage, car alarms, air tools etc.
Only 36 seconds without ear defenders can cause damage.
12

Occupational cancer - many service
technicians each year get skin cancer.
Repetitive strain injury, tennis elbow,
etc.
Stress - people who tend to be quiet
and bottle things up are more prone.
COMPENSATION MAY SOUND GOOD,
BUT IT WILL NOT GIVE YOU BACK YOUR
HEALTH
13

Safety in the collision repair shop is the
responsibility of everyone.
Safety means protecting yourself and
others from injury at all times.
Working in the collision shop requires
the use of a large variety of materials
and equipment that can injure the
worker and others in the shop if not
properly handled.
RESPONSIBILITY FOR SAFETY
14

Good Safety behaviour in the shop
includes the following:
Following legislation guidelines for safe
practices
Keeping the shop free of hazards
Using protective clothing and
equipment
Handling and using materials
containing potentially harmful
chemicals correctly
Using hand tools, power tools, and
equipment correctly
Following welding safety rules
RESPONSIBILITY FOR SAFETY
15

During the course of working in the
shop, a collision repair technician moves
from one area of the shop to another,
moving parts and equipment around
the shop and performing a variety of
tasks.
It is important that the shop floor be
free of hazards that could cause
technicians to slip, or trip.
In a wide variety of shop tasks, waste
materials are produced that can cause
dangerous situations and hazards
unless the waste materials are disposed
of, or stored, correctly.
GENERAL SAFETY RULES
16

Always be sure that shop exits are well-
marked with an “EXIT”sign and are
clear of obstructions.
For personal safety and to help keep the
shop free of hazards, always comply
with the following safety rules.
MAINTAINING A CLEAN WORKSHOP
17

Does this workshop look safe?
In the small area pictured there are
many hazards.
Can you point some of these out?
18

Another example of a poorly
maintained workshop.
Discuss some of the potential hazards
that could exist in a workshop that is
not cleaned and maintained regularly.
19

Good housekeeping promotes a safe
workplace.
Fire exits wont be blocked.
Hazardous materials and waste will be
stored correctly.
It promotes a professional image.
Workers are happier to work in a clean,
safe environment.
There will be less accidents such as trips
or hazards in the shape of spillages.
20

MSDS are documents provided by the
manufacturers and suppliers of
chemicals to inform the end user on the
chemical composition and what to do in
case exposure occurs.
The MSDS should be located in the
workshop for every technician to
access.
Lack of access to MSDS on the shop
floor can mean the difference between
life and death, as time is of the essence
when identifying how to treat an injury
or mistake.
MATERIALS SAFETY DATA SHEET (MSDS)
21

PPE is the abbreviation for personal
protective equipment
Having a clean workshop is one thing
but you also need to make sure that you
work safely at all times.
The first thing to do is to make sure
that you always have the correct PPE to
carry out a specific task.
Some PPE has to be worn all the time -
from the moment that you enter the
workshop
PPE
22

General principles:
PPE must be provided by the employer
PPE must be used when directed by
your employer
PPE is a protection measure, as a last
resort
PPE is:
Overalls (worn at all times)
Safety shoes/boots (worn at all times)
Eye protection
Hand protection
Ear protection
Head protection
PPE
23

Worn when carrying out sanding,
cutting, grinding and drilling operations
EYE PROTECTION
24

Overalls should be worn all the time
within the workplace and should be fire
retardant.
Never blow off overalls with
compressed air as this will oxygenate
them (they would burn better in a fire).
Aprons are normally used when
carrying out specific operations such as
welding.
OVERALLS AND APRONS
25

Safety boots/shoes should be worn at
all times in the workshop.
They should have a steel toe cap and
ideally be alkaline resistant.
SAFETY BOOTS/SHOES
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To protect against noise levels within
the workshop.
For example: an air saw can be
measured at above 85 decibels and this
level of noise begins to damage ears in
less than 10 seconds.
EAR PROTECTION
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Gloves to be worn for specific tasks
such as:
sanding
grinding
welding
chiseling
drilling
and handling chemicals.
GLOVES
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Masks should be worn if carrying out
spray painting activities or when
sanding.
MASKS
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Fire needs 3 things to burn!
Fuel, Oxygen and Heat.
FIRE
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FIRE
If you take one thing out of the cycle the fire will go out!
31

In some cases a small fire can be tackled
with care.
If the fire is large and the potential to
spread is evident then raise the alarm,
get out and stay out!
The content of each extinguisher is
indicated by a contrasting colour band
on the cylinder.
Not all types of extinguisher can be
used on all fires - some can make
matters worse!
Be aware of the differences.
FIRE
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FIRE
Type Item Description Use on
Water RED Solid fuels
Foam CREAM Flammable liquids and liquefiable solids
Dry powder BLUE
Flammable liquids and liquefiable solids
Flammable and liquefied gases
Carbon dioxide BLACK Flammable and liquefied gases
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To use
Pull Out Safety Pin
Aim Nozzle at base of Fire
Squeeze Handle
FIRE
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SIGNS AND LABELS
Mandatory
Must do
35

SIGNS AND LABELS
Prohibited
Must not
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Signs and labels
INFORMATION SIGNS - CAN YOU NAME THESE?
37

Signs and labels
WARNING SIGNS
Explosive materials
Flammable materials or high temperatures
Corrosive materials Danger: Electricity
38

SIGNS AND LABELS
This sign can also
be found written
as harmful
39

When sanding dust extraction should be
used to protect both yourself and others
around you.
SAFETY EQUIPMENT AND WORKING SAFELY
When welding fume extraction should
be used to protect yourself and others
around you.
Note: Secondary protection such as a
mask should also be worn.
40

Before using any workshop tools or equipment make sure it is in working order.
For example: no loose parts, split wires, oil leaks.
If there is a problem do not use it. Label it and inform your supervisor.
Note: Make sure hand tools are checked before use.
41

Work safely at all times and don’t take
chances.
For example:
When raising a vehicle, never go under
it until the stands have been placed
securely.
Never grind without wearing goggles.
Never weld without using a mask and
fitted with the correct grade lense.
Be mindful of others around you.
Use common sense and stay safe!
42

Electrical equipment
Lifting, jacking and the supporting of
vehicles
Inappropriate behaviour
Failing to use appropriate PPE
NAME A POSSIBLE HAZARD ASSOCIATED WITH
43

What is meant by the term PPE?
A) Personal Protective Equipment
PPE?
44

What items of PPE and/or equipment
would be used when carrying out the
following operations:
Grinding?
Sanding down body filler?
Spray painting a vehicle panel?
Using a dual action sander?
PPE
45

Safety glasses
Visor
Safety helmet
Welding mask/helmet
Ear defenders
Ear plugs
Overalls
Safety shoes/boots
Dust mask
Air-fed mask
Gauntlets
Chemical gloves
Nitril Gloves
NAME 5 ITEMS OF PPE
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HEALTH AND SAFETY
You find that an air powered tool is unfit for use what should you do?
47

HEALTH AND SAFETY
A hydraulic jack is leaking oil, why should you not use it?
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HEALTH AND SAFETY
If a spillage of oil occurs within the workshop why should it be cleaned up immediately?
A) Prevent slips/accidents
49

What colour identification label would
the following fire extinguishers have?
Water
Foam
CO2
Powder
TYPE OF EXTINGUISHERS
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HEALTH AND SAFETY
On what type of fire would you use a water filled extinguisher?
Paper
Wood
Textiles
51

What possible health risk could occur
when handling solvents without the
use of gloves?
Skin disorders such as dermatitis
EXPOSURE TO CHEMICALS
52

NAME THESE GROUPS OF SIGNS
Mandatory and prohibited
53

Name 3 hazardous substances that you
are likely to encounter within the
workshop.
Paint
Thinners
Degreaser
Dust
Sealants
3 HAZARDOUS SUBSTANCES
54

What does this sign state?
A) Toxic substance
SIGNS AND LABELS
What does this sign state
A) Corrosive substance
55

With what piece of equipment should
you support a vehicle with after jacking
it up in preparation to remove a wheel?
A) An Axle Stand or another sort of
dedicated support equipment
HEALTH AND SAFETY
56

HEALTH AND SAFETY
Name 4 potential hazards within the workshop.
Write down what you think they are and discuss.
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Why is it important to leave your work area clean and tidy after use?
HEALTH AND SAFETY
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LESSON 1 SUMMARY - HEALTH AND SAFETY
You have reached the end of this lesson.
You should now be able to:
Be aware of your safety environment
and of others
Protect your self from harmful
situations
Understand that some health issues are
caused by long term exposure
Know what is the right safety
equipment to use
Know what to do in case of fire
Identify signage and protect yourself in
that environment
Understand why you need to work in a
clean workshop
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INTRODUCTIONLESSON 2
DAY 1 – PA RT 2
WO R KS H O P TO O LS
&
E Q U I PM E N T
61

If you see this sign this means that it is a point to note!
KEY POINTS
62

A wide range of tools and equipment is required to carry out non-structural repairs
and repairs cosmetic in nature.
Each tool or item of equipment will have a specific use to ensure correct completion of
a specific task.
TOOLS FOR BODY WORK
63

The Poziriv screwdriver is designed to
decrease the chances of slipping out and
helps to provide a greater driving surface
and decrease wear and tear.
The Pozidrive screwdriver should be used
in conjunction with pozidriv screws.
HAND TOOLS SCREWDRIVERS
The slot (flat) blade screwdriver for use
with slotted head screws.
This does not afford as much driving
force as a Pozidriv or Phillips (cross slot)
type.
64

The cross slot type screwdriver.
As with the Pozi it helps to provide a
greater driving surface and decrease wear
and tear.
As with the Pozi it helps to provide a
greater driving surface and decrease
wear and tear.
Less force is able to be applied than a
torx head.
65

Screwdrivers available in various
lengths to allow better access in
confined areas
Screwdrivers are also available angled,
also to allow for better access in
confined areas
There are even‘ratchet’ type
screwdrivers, with interchangeable tips
67

This tool is simple, small and light.
The contact surfaces of screws and
bolts are protected from external
damage.
There are six contact surfaces between
bolt and driver.
The tool can be used with a headless
screw.
The screw can be inserted into its hole
using the key.
Torque is constrained by the length and
thickness of the key and very small bolt
heads can be accommodated.
ALLEN KEY (HEX HEAD) SETS
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Combination Spanner
Open end/ring
HAND TOOLS SPANNERS
Open ended spanner
69

Combination, Flex Head/Open End
HAND TOOLS SPANNERS
Twin ring spanner
70

Combination open end ratcheting ring
HAND TOOLS SPANNERS
Flex Head Spanner
71

Adjustable Spanner (Shifting)
HAND TOOLS ADJUSTABLE SPANNERS
Make sure you use the correct size
spanner!
72

Ratchet
HAND TOOLS SPANNERS
Ratchet with bent handle and swivel
head used for access
73

SOCKETS
12-Point Socket6-Point Deep Socket
Torx Socket
74

RATCHET ACCESSORIES
Adaptors
Extension Bars
Swivel Joints
75

IMPACT DRIVER AND SOCKETS
Heavy duty drivers and sockets for over-tightened bolts
76

MARKING OUT TOOLS, MEASURING AND CUTTING
Engineers Square
Steel Rule
Scribe
Dividers
77

Hacksaw Vernier Gauge/Caliper
Centre Punch Tape Measure
78

Metal Cutting Shears
Red - Left hand cut
Yellow - Straight cut
Green - Right cut
79

PLIERS
Combination Pliers Long Nose Pliers Multi Grip Pliers
80

FILES & HOLDERS
Metal Files for smoothing
Dreadnaught Files for metal
finishing and putty shaping
81

SELF LOCKING GRIPS
Vice grips/self locking clamps/welding clamps
84

HAMMERS AND MALLETS
Copperand Hide Hammer
Claw Hammer
Ball Pein Hammer
85

HAMMERS AND MALLETS
Rubber Mallet
Rubber Mallet
Nylon Hammer
86

Wooden Mallets
HAMMERS AND MALLETS
87
Tinsmans Bossing/Pear

HAND TOOLS AND THEIR USE
Select the tools that you will need for carrying out the repairs
How many can you name?
Spoon dolly
Dolly
Body file
Bumping blade
Hammer
88

What is this tools name?
Bumping blade.
What is it used for?
Raising low spots and levelling a panels
surface.
How is it used?
A dolly is normally placed behind the
panel (underside) and the bumping
blade is used to strike the surface. Its
milled face (like a file) helps to stop
stretching of the panel.The areas
around the low points are struck which
draws them back into shape.
89

What are these tools called?
Hand dollies or dolly blocks.
What are they used for?
Raising low spots and levelling a panels
surface.
How are they used?
A dolly is normally placed behind the
panel (underside) and a hammer or
bumping blade is used in conjunction
with them.When used with a hammer
plannishing can take place.
When a hammer is used directly above
a dolly it is called direct hammering and
when ‘off’ the dolly this called in-direct
hammering.
90

Dollies come in many shapes and sizes
and each with a specific use
Can you state how each of these three
could be used?
91

Panel beating hammers
We shall introduce and discuss the
different hammers and their uses
92

What is this tool called?
Adjustable body file.
What is its use?
To file body panels and to identify high and
low spots.
In some cases a metal finish can be obtained
without the need to use body filler.
How is it used?
After using a bumping blade, and/or carrying
out plannishing, the body of the file is
adjusted to the profile of the panel.The file is
moved back and forth over the damaged
area - but remember to change to direction
to keep your work uniform.
When you file across the repair this
technique is called ‘cross filing’ and working
in a straight line is called ‘line filing’.
93

AIR (PNEUMATIC) TOOLS
Air Powered Drill
This tool is used mainly for drilling
operations but other tool attachments
may be used.
Replacing a drill bit with a wire wheel
can enable the tool to be used as an
electrical wire brush.
Most drills can also operate in reverse
by adjusting a switch.
94

Electrically Powered Drill
This tool is primarily used for drilling,
but, as with the air drill, can be used for
other applications.
Because of the drill being electrically
powered, with a higher torque, greater
care must be taken when using it.
Electrical drills can also operate in
reverse, using a similar switch to the air
drill.
POWER TOOLS
95

A selection of drill bits for drilling
metals.
They are available in many different
sizes.
There are also specialised drill bits
available for drilling out spot welds, to
be used when removing structural
welded panels and other drill bits for
working with high strength steels.
DRILL BITS
96

Cone cutting tool.
Use mainly for the enlarging/cutting of
pre-drilled holes.
Eg. Aerial holes
CONE CUTTING DRILL
98

It is mainly used for cleaning/blowing
away dust from crevices, gaps and
apertures prior to refinishing.
Can also be used for drying small areas.
AIR BLOWER
99

Used for the accurate drilling of
components and parts
Clamp attaches to table to hold pieces
securely
PEDESTAL DRILL
Pillar Drill
100

Wheel dollies or skates
Mainly used for moving vehicles with
damaged suspension.
AXLE STANDS & WHEEL DOLLIES
Axle stands
For supporting vehicles at a specific
height, with or without wheels in place.
101

Hydraulic jacks
Mainly used for lifting/supporting
vehicles at height.
HYDRAULIC JACKS
102

A range of hydraulic lifting equipment
HYDRAULIC LIFTING EQUIPMENT
104

Hydraulic ram – commonly known as
‘Porto-power’.
For pushing, pulling and re-aligning
vehicle bodies.
HYDRAULIC RAMS
105

A small range of equipment as well as
consumables in dry sanding.
Sanding block
Dual action sander – commonly known
as a‘DA’sander
Sanding disc, for use with a DA – note
the holes to allow for dust extraction
Portable dust extraction equipment
Other abrasive materials
DRY SANDING EQUIPMENT & MATERIAL
106

Double-action sander
INDUSTRIAL GRADE SANDING EQUIPMENT
Orbital sander (Desirable)
107

INDUSTRIAL GRADE SANDING EQUIPMENT
Various sanding blocks
Sanding fileBelt sander
108

Air compressor
For storing providing compressed air
and then releasing it on demand to
power‘air’ tools and spraying
equipment.
COMPRESSED AIR
109

An air compressor is a device used to
squeeze air into a smaller space by
compressing it.
The air is then channelled through a
series of pipes and filters until it
reaches an outlet, which enables the
connection of air powered tools.
There are many different types of
compressor and as you progress
through the levels of the vehicle body
and paint courses you will learn more
about these and their use.
COMPRESSED AIR
110

Air Compressor
Air Holding Tank Water Receiver Dryer
COMPRESSED AIR SYSTEM
111

For the removal of water and oil in
airlines
These need to be checked and drained
on a regular basis
There is the facility to control the
pressure of the air supplied at the
outlet
OIL & WATER SEPARATOR
112

INFRA-RED DRYING LIGHTS
Portable infra-red drier.
Used for the drying of paint products,
bodyfiller and other consumable
products such as sealants and
adhesives.
Infra-red is a very radiant form of
heating. A good infra-red heat source
has the ability to heat objects directly,
without having to heat the air in
between.
Infra-red heating is generally split into
three categories: Short-wave, Medium-
wave and Long-wave.
113

Vehicle lift/ramp.
Mainly used for raising heavier vehicles
so that work can be carried out at
height in a safe manner.
A four post ramp
4-POST VEHICLE LIFT
114

A two post vehicle lift.
Used in the same manner as a 4-post
lift, but gives better access to certain
areas of the vehicle ie wheels and
suspension.
These lifts do not generally have as high
a maximum lifting weight as a 4-post
lift.
2-POST VEHICLE LIFT
115

Oxy-acetylene gas welder (mixed
oxygen and acetylene gas)
Mainly used for Heat Shrinking
No longer suitable for welding modern
day steels
Stud welder (for drawer work) For
pulling out dents where there is poor
access to the underside of a panel
EQUIPMENT REQUIRED FOR NON STRUCTURAL WORK
116

EQUIPMENT FOR WORKSHOP ORDER
Waste oil draining
equipment
Waste
material site
System cargo (large basket for parts storage)
117

You have reached the end of this lesson. You should now be able to:
Have a broad understanding of the
types of tools used for non-structural
repairs in a bodyshop
Be able to identify these tools
Have knowledge of certain safety
aspects in the use of the tools
LESSON 2 SUMMARY – TOOLS AND EQUIPMENT
LETS LOOK AT SOME TOOLS!
119

INTRODUCTIONLesson 3
DAY 2 – PA RT 1
M E TA L C H A R A C T E R I ST I C S
121

The complexity of the repair method
will depend on the complexity of the
damage.
In some cases there may be only one
relatively simple step in roughing out
the panel.
In other cases a number of different
methods and many different steps may
be required to perform the rough out
procedure.
The damage shown here may well
require the use of pulling equipment.
Access to this damaged area is likely to
be very limited.
UNDERSTANDING SHEET METAL DAMAGE
122

1. Effects of bending sheet metal
a. Surface on the outside of the bend becomes stretched.
b. Surface on inside of the bend becomes compressed.
123

When metal is bent it becomes harder.
The effect of bending metal, thereby making it harder, is called work hardening.
All metal is work-hardened when it is formed into vehicle parts.The more bend is given
to the metal the harder it becomes (provided the metal is not stretched or compressed
beyond its yield point).
Metal also becomes harder when struck with hammer blows, as during a panel repair.
Work-hardened metal is under stress. If the work hardening is a result of the accident
and must be removed, then this stress must be relieved.
124

Types of stress relief
Heat relief is accomplished by heating the metal with an oxyacetylene torch (within
the guidelines of the metal being heated).
(CAUTION: Do not heat metal until you know the exact type of metal being worked on
and the limit to which it can be heated. High strength steel has very specific heating
limitations).
Shock relief is accomplished by striking the metal with a hammer while pressure is
applied, either with a dolly, spoon or a hydraulic body jack).
125

126

Key properties of metal allowing them to change shape:
Plasticity — The ability to be forced into a new shape without breaking.When sheet
metal is formed in a press, it is said to have undergone plastic deformation, meaning
that under pressure the metal has flowed into a new shape.
(NOTE:Work-hardened metals retain plasticity, but the degree of their plasticity has
been changed).
Yield point — Point that metal will stop flowing under pressure and will break.
Ductility — The ability of metal to be stretched without breaking.
Malleability — The ability of metal to be compressed without breaking.
Elastic limit — Amount of bending metal can undergo without deforming.
127

Classifying and repairing damage
Basic types of metal panel damage
A - Tears or holes
Tears and holes occur after the metal has been stretched beyond its yield point.
Smaller tears and holes will not greatly effect the overall strength of the panel and can
be repaired by welding, patching or filling.
B - Bends
Bends occur after the metal has been stretched or compressed beyond its elastic limit.
Bends must be repaired by carefully working the metal back into shape, using various
methods covered later in this unit.The bend is sometimes called the "buckle.”
The complex shapes used in the design of most vehicle panels result in complex buckles
in a collision – some are intentionally placed to form a‘crumple zone’.This means that
the panel deforms in a structured way, protecting other areas of the vehicle – like the
passenger compartment.
128

A flat surface, when bent, results in stretch at the top of the bend and compression at
the bottom.
129

An open box section component, when bent, results in simple stretch at the top of the
bend and compression wrinkles at the bottom.
130

Actual damage to vehicle panels generally results in compression wrinkles of two
types, known as "rolled buckles," and "hinge buckles."
131

Rolled buckles usually occur in areas where the metal has a crowned surface. In a rolled
buckle, all of the metal along the buckle has been stretched and compressed.
Rolled buckles tend to end at some point in the crown with a sharp dent.The ridge
above this dent is called an "eyebrow.“
Hinge buckles occur as a bending or pivot point from which two areas of relatively
undamaged metal have moved or shifted.
132

You have reached the end of this lesson.
You should now be able to:
Understand characteristics of metals in
non-structural repair
Understand how this engineering
applies to body repair techniques
Use this knowledge to perform dent
repairs in a logical way
LESSON 3 SUMMARY – CHARACTERISTICS OF METAL
133

DAY 2 – PA RT 2
S H R I N K I N G
134

Sometimes a panel may have stretched
and will require shrinking.
Stretching occurs for two main reasons:
1. A panel that has a large deep repair
may have become‘stretched’ during the
collision.
2.You may have overworked a panel
during the repair and it has become
stretched.
How do we overcome this?
We shall look at a number of different
methods.
SHRINKING
135

The first is by using an Oxy/Acetylene
welding plant.
Most manufacturers would no longer
recommend this method as the steels
used in vehicle construction no longer
react well with such intense heat.
For example an Oxy/Acetylene plant
can deliver 3200 deg and will damage a
high strength steel (HSS) panel,
breaking down the molecular structure
and making the steel brittle.
Some HSS panels can be damaged with
heat in excess of 1200°C.
SHRINKING
136

Traditionally the high spot/s were
heated until cherry red.
Panel
Damage
High spot heated until cherry red
approx. 5-10mm diameter
SHRINKING
137

Using a dolly to support the underside,
take a panel hammer and starting
outside of the heat zone planish the
panel carefully gradually moving
inwards to the centre.
This forces the grain structure of the
steel toward the weakest point-the
point you just applied the heat to.
Route of your hammer blows
SHRINKING
138

After each application of heat and
planishing the area was cooled with a
cold water soaked cloth to cool it
rapidly.
This cooling would stop the grain
structure from falling back into its
‘stretched’ condition.
This would be repeated until the panel
had stopped wobbling/become more
stable.
Then proceed with traditional repair
methods once stabilised; perhaps body
filler.
SHRINKING
139

Another method of carrying out
shrinking work would be with a carbon
arc shrinking rod.
The panel will need to have the
machine’s earth lead attached and the
repair area needs to be clean.
The rod is normally passed over the
‘high’ area in a spiral or zig zag motion.
Carbon is imparted to the panel which
makes it stronger and less moveable so
that it can be worked on.The high area
is taken down level without causing any
further stretching.
SHRINKING
140

The carbon rod can be an extra attachment on either spot welding machines or dent
pulling machines.
Settings can be defined on the relevant machines according to the material you are
working on.
Always check technical information to ensure the settings match the steel to be
worked on.
SHRINKING
141

A more up to date method of shrinking
is with an induction heater.
An induction heater allows a greater
level of control over the heat input and
is relatively easier to use than other
methods of shrinking.
An induction heater can also be used in
other areas of body repair.
SHRINKING
142

An area of damage found on a new
quarter panel.
We could use a hammer and dolly using
normal methods but it is likely
stretched already and we could
potentially make it worse.
SHRINKING
143

Set the parameters on the machine
being sure that you know what the
base material is move the heating
element over the damaged area.
This will only take a few seconds as heat
is rapidly transferred.
SHRINKING
144

Use a hammer and dolly and work
around the repair.
Do not concentrate on one area but
make sure the hammer blows are
spread about.
Cooling can be done when you are
happy with the shape and profile.
SHRINKING
145

A visible charred mark remains but the
panel is now flat and to the correct
profile.
Metal finishing or body filler can be
used to complete the repair but make
sure the area is thoroughly clean first.
SHRINKING
146

Understand the type of tools used for
shrinking
Understand the methods used for
shrinking
Understand the purpose of shrinking
LESSON 4 SUMMARY - SHRINKING
147
LET’S PRACTICE

DAY 2 – PA RT 3
R O U G H I N G O U T
T E C H N I Q U E S
148

Rough out refers to the process of
re-shaping damaged panels close to
their original contours and alignment.
Each situation will require a unique
combination of methods. In the case of
moveable panels repaired off the
vehicle, correct alignment is performed
after rough out procedures.
NOTE:The term "rough out" is
somewhat misleading. The dimensions
must be very accurate, even if the metal
panels still look rough prior to metal
finishing operations.
ROUGHING OUT TECHNIQUES
149

Due to the unique nature of each
collision, there is no one way to rough
out panels.There tends to be
considerable overlap between the
operation of roughing out, panel
alignment and metal finishing.
A repair on a wing such as would need
to be roughed out first before filing or
using body fillers.
To rough out means forming the rough
shape of what the panel was prior to
the damage.
150

Before the repair process begins we will
need to look at the tools required to
carry out this work.
Using body hammers, spoons, and
dollies.
Used in many repairs as the final
procedure prior to plastic filling,
regardless of which other methods are
employed.
Body hammers, spoons, and dollies are
also tools that are used in performing
other methods of repair.
151

Using pry bars.
Used in situations where the back of a
panel is not easily accessible.
152

Nail welding gun and dent pulling
equipment.
Used to weld nails, tags or washers on
or around a dented area. A pulling
device is then attached to these to pull
out the dent.
Many different ones are available.
153

Using hydraulic equipment — Often
used on quarter panels, and some other
stationary panels, as a first step in
returning a severely damaged panel
back to its proper dimensions.
NOTE: In repairing the damage to any
panel, the damage must be repaired in
the opposite sequence that it occurred.
The last damage caused by the collision
is the first damage that should be
removed.
154

Body hammers are designed to rebound
off the sheet metal surface after
striking it. Use of these body hammers
is not difficult, but it requires some
practice.The technician must be come
accustomed to the different motion
used in the quick tap technique of
striking sheet metal.
The correct hammer must be used for
the job and mastery of using the
hammer with the dolly must be
achieved.
NOTE: Body hammers should be well-
cared for and not used for anything
other than their intended purpose.
Do not use them as hammers.
USING BODY HAMMERS
155

The main aim when roughing out sheet
metal damage should be to save the
panel.
Hard hammer blows cause new dents in
the sheet metal.
Light, rebounding blows should be used
to prevent additional damage to the
panel.
If the metal is workable, it will come
back into shape easily without use of
excessive force.
USING BODY HAMMERS
156

Before commencing any panel repairs
check the underside for sound
deadening material.
To try any repairs with this material in
place could stretch the panel.
157

When striking a blow, the body hammer
should be held loosely in the hand by
the end of the handle, and it should
rebound from the metal as the blow is
struck.
It is more of a ‘wrist action’ than an ‘arm
action’ .
Space each hammer blow about 1/2
inch apart, and continue hammering
until the dent has been realigned.
158
Using body hammers

If the damage is more severe then the
use of a larger hammer may be needed
but again, care will be needed not to
cause irreversible damage by stretching
the steel.
Wooden mallets can also be used, as
these have a much softer face than
steel hammers and they will cause
much less damage to the panel during
repair - less chance of the panel then
being stretched further.
USING BODY HAMMERS
159

Dollies should be used in conjunction
with hammers on most occasions.
The dolly is used as support on the
underside of the panel you are
hammering.
The dolly block can also be used to
‘push’upwards helping to level the
surface and to offer tension.
By using the dolly block you will prevent
the damage from encroaching further
and becoming deeper. It will also help
prevent stretching.
USING BODY DOLLIES
160

USING BODY DOLLIES
Dollies come in a variety of shapes and sizes and to use simply choose the one that ‘fits’
the damaged area.
Dollies can have crowned faces, flat faces and straight edges to fit against different
types of damage when working.
For example, a straight edge may be used when working on a swage line.
Some dolly types are known as spoons because of their shape and these are more
commonly used in hard to reach areas.
161

HAMMER AND DOLLY KITS
Different panel repair kits showing a range of hammer, dolly and spoon types
162

Some dolly types will have a very
specific use however.
Milled face type.When the steel is
hammered against the dolly, it is forced
onto the surface causing the damaged
area to tighten.
Groove face type.When the steel is
hammered against the dolly, it is forced
into the groove, again causing the
damaged panel to tighten.
Note: these should be used with great
care. Metal finishing cannot be
completed with the use of these.
USING BODY DOLLIES
163

Sometimes the dolly will be used directly under the hammer.When struck you should
here the dolly ‘ding’. Remember when roughing you may be using different hammers
according to the type of damage.
USING THE HAMMER AND DOLLY
164

The dolly here is being used to push up against the low area prior to using a hammer.
To hammer a panel straight away with a great deal of depth will hinder you.
165

Direct hammering is also referred to as
‘on the dolly’. Both hammer and dolly
being used in line with each other.
As you move around the repair the two
should follow each other exactly.
166

In-direct hammering often referred to as ‘off the dolly’.
The hammer is used on high areas and the dolly is used to push against and support
lower areas.
167

Spring hammering.
The hammer is struck against the spoon
dolly directly onto the damage.
Normally the damage will be crowned
in nature.
This technique is especially useful when
working on a large panel with little
access, such as a hood or roof.
168

High spots can be tackled with the pick
hammer both with and without the use
of a dolly.
Several attempts with the bumping
blade, hammer and file will take place
until the surface is at a point you are
happy with.
You may of achieved a‘metal finish’ if
not then body filly can be used to
complete the repair.
169

The bumping blade is another tool for
raising low spots.
It has a milled face the same as a
regular metal file.
The tool is to be used by striking down
with the flat face while a dolly is used
as support on the underside of the
panel.
With patience and precise hitting, this
tool can produce some very good
results.
170

The spoon dolly shown in this graphic is being used in an area that a dolly block cannot
be used in.
This tool can also be used for prying in certain circumstances.
171

roughing out
roughing out
Understand the purpose of roughing
out
LESSON 5 SUMMARY – ROUGHING OUT
173
LET’S PRACTICE

DAY 3 – PA RT 1
D E N T P U L L I N G
175

A lot of the repairs we undertake can be
straightforward.
Dent to fenders, doors, hoods and rear
quarter panels can allow good access
for us to use our hammers, dollies,
spoons and bumping blades.
But what if access is limited?
What if the damage is to a rocker
panel?
What if the damage is to a double
skinned wheel arch?
DENT PULLING
176

The answer is to use a dent puller
Suction cups can be used but they only
have a limited capability and only work
effectively on shallow dents in large
panels, such as a roof
DENT PULLING
177

Some are known as line pullers and can
work by simultaneously pulling across a
large area.
DENT PULLING
Some machines are single point pullers
with a slide hammer attachment.
178

The attachment shown here is a single
point puller but has a foot that rests
against the panel allowing the puller to
push against it.
This has the effect of pulling a low spot
level whilst at the same time keeping
the surrounding panel level also.
DENT PULLING
179

A line puller such as this one works by
being attached to a series of rings or
washers that have been welded into an
area of damage.
DENT PULLING
180

DENT PULLING
Firstly make sure the area to be worked on is thoroughly cleaned and free from paint,
rust, grease and any other contaminants
.
181

Set the parameters on the machine
taking into account the thickness of the
material you are working on.
As you can see, there are a number of
settings to be considered!
DENT PULLING
182

Ensure there is a clean area is available
to attach the earth clamp.
Start welding into place a series of
rings, P rings or washers - depending on
the system you are using and the type
of damage.
DENT PULLING
183

DENT PULLING
When working on a large dent the spacing of rings is critical to achieving the best
results. On the left of the graphic small spacing leads to an even pull with pressure
spread across the damaged panel. On the right large spacing clearly highlights an
uneven pull on the panel.
184

A rod will need to be inserted through
the rings once they are welded in place.
Choose a suitable size and length.
DENT PULLING
185

Adjustments may need to be made after
each pull is made as it is not wise to try
and get the panel level in one go.
It is a gradual process
DENT PULLING
Attach the puller to the centre of the
rings. It will hook around the bar.The flat
feet at either end must be snug against
the panel and pulling can commence.
186

DENT PULLING
With tension in place, any ridge or high spot can now be worked on.
This will also help relieve any stress in the panel and allow for the dent to move more
freely when pulling.
187

Keep checking the panel as you work with the flat of your hand.
It is also good practice to use a straight edge when working on a large area.
DENT PULLING
188

Small areas of low spots can be
removed using a slide hammer
attachment.
This welds a tip to the panel and allows
very precise pulling in conjunction with
the line puller.
Mark the area to be pulled prior to
beginning the activity.
DENT PULLING
189

Individual pulls can be made using the slide hammer. A twisting action will break it free
so that you can immediately attach it to another point.
DENT PULLING
190

After all the pulls have been made and the panel is now returned to its correct profile
the rings can be removed with a simple twisting action.
Sand any areas that have remnants of a ring and also any burn marks.
DENT PULLING
191

DENT PULLING
The repair is now ready to be completed by using body filler.
A lot of time has been saved from not having to fit a new panel and damage any factory
seals.
192

To get a perfectly straight panel on an
area such as this might mean attaching
the puller at many points but it does not
take much time at all.
DENT PULLING
A single point puller in use on a rear
quarter panel.
This repair is smaller so a line puller is
not required.
193

DENT PULLING
This dent puller is known as a slide hammer.They normally have a variety of
attachments, such as hooks for pulling out the edge of a wheel arch.
These can be used in conjunction with other pullers.
A drawback of this type is the need to drill a hole for and single point pulling. This hole
then needs to be welded and the finish is seldom as good as electronic pullers.
194

dent pulling
Understand the methods used for dent
pulling
Understand the purpose of dent
pulling and how different ways can
achieve the same result
LESSON 6 SUMMARY – DENT PULLING
196
LET’S PRACTICE

DAY 3 – PA RT 2
B O DY F I L I N G A N D M E TA L
F I N I S H I N G
197

Repairs to panels are often completed
using body filler.
Prior to filling the process of levelling
and planishing can also be aided by
using a body file.
In some cases a repair can be fully
completed by filing so long as the
integrity of the panel is not affected.
Remember sheet metal used for panels
is only usually between 0.7mm and
1mm on modern vehicles.
BODY FILING AND METAL FINISHING
Body file
198

What is its use?
To file body panels and to identify high
and low spots in a panel.
In some cases a metal finish can be
obtained without the need to use body
filler.
This takes a great deal of skill and
practice and can only be achieved on
certain panels due to the gauge
(thickness) of the metal.
199

The file holder itself comes in two
shapes, flat and half-round.
The file blades can come in a number of
coarse cuts and are generally 14 inches
in length. Some smaller ones for
smaller holders are sometimes used.
Each file blade has a holes at either end.
This allows the blade to be fixed in
place on the holder with the use of
countersunk screws.
200

The coarseness of the blade is
determined by the spaces between each
of the cutting edges.
The space between them is known as
the pitch.
The more edges there are the less
coarse the blade will be.
Spacing of cutting edges
201

Different file holders for different uses
Adjustable flat file
holder allows filing of
convex and concave
areas
Non adjustable flat
file holder allows
filing of flat areas
Half round file holder
for use on
curved/recessed areas
202

How is it used
Underside of file showing fixing holes and screws for retaining the blade to the holder.
Remember the screws are countersunk, so will not catch the surface when the file is
being used.
Using the wrong type of screw will damage the surface
203

How is it used
After roughing out and planishing with
a hammer and dolly the file is used to
file the surface of the repair area.The
file will cut the surface better if paint
has been removed and the repaired
area is bare metal.
Bare metal with visible work marks
from planishing.
Painted area outside repair area.
204

How is it used
If your body file holder is of the
adjustable type (as shown) then adjust
the central nut and achieve the correct
profile for the panel.
An incorrect profile will not achieve
the required results.
205

How is it used
In this image we can see the curvature
of the file after adjustment which best
fits the shape and curvature of this
panel being repaired.
206

Here we see the opposite adjustment. Clearly it is the wrong one for this surface. Some
would say “but it cuts better” this is an incorrect statement as it will not file a flat
shape.
How is it used
207

How is it used
Once the adjustment is made you are
ready. It is best to hold the file with
both hands to ensure continued and
even contact with the surface.
208

How is it used
Push the file forward across the repair.
For best results do not drag back but
rather lift, place back at the edge of the
repair and push forward again.
This will minimise the amount of
scratching to the surface.
Continually file over the repair moving
across the cover the entire spot.
Take an amount of time to do this as
changes to the surface will not happen
very quickly.
209

How is it used
If we change direction with the file a
file across the repair then this is called
cross filing.This technique will actually
cover more surface area.
210

One drawback of filing is scratches it
causes to the panel.
However, if the file is used correctly
then this is minimised and most of
these can be removed with a Dual
Action sander afterwards - or a very
fine putty can be used, if necessary.
Note:Take care not to turn the file on its
edge as this will cut a far deeper
scratch.
211

The filing action will reveal any low
spots and high spots.
Low spots will be dull looking and have
fewer scratch marks evident.
High spots will be shiny in appearance
as the file has run over these areas
without touching the low spots.
The technician’s job is to try and level
the surface to remove any high or low
spots.
212

Further work may be needed using your
panel hammer combined with placing a
dolly on the underside of the panel.
When the shape is almost correct then
great care needs to be taken not to
undo any of the good work completed
so far.
213

LESSON 7 SUMMARY – BODY FILING & METAL FINISHING
metal finishing
metal finishing
Understand the purpose of metal
finishing
215
LET’S PRACTICE

DAY 4 – PA RT 1
I N T R O D U C T I O N TO
A L U M I N I U M R E PA I R
217

A brief history
Aluminium has been used within the
manufacture of vehicles for a
considerable amount of time.
Initially it was mainly used for
conventional panels wings, bonnets
and doors.
ALUMINIUM PANEL REPAIR TECHNIQUES
218

Aluminium is soft, lightweight,
fire-proof and heat-resistant, easy to
work into new shapes, and able to
conduct electricity.
It reflects light and heat very effectively
and it doesn't rust. It reacts easily with
other chemical elements, especially
oxygen, and readily forms an outer
layer of aluminium oxide if you leave it
in the open air.
These are referred to as aluminium's
physical and chemical properties.
219

Aluminium really comes into its own when you combine it with other metals to make
aluminium alloys (an alloy is a metal mixed together with other elements to make a
new material with improved properties. For example, it might be stronger or it might
melt at a higher temperature).
A few of the metals commonly used to make aluminium alloys include boron, copper,
lithium, magnesium, manganese, silicon, tin, and zinc.
Aluminium is mixed with one or more of these, depending on the properties that the
aluminium alloy needs to have.
220

The passenger car of today, and certainly the car of the future, has to satisfy very high
demands. Aside from being a high performance vehicle, that ensures driving ease,
safety and comfort, it has to comply with strict and necessary environmental demands.
This environmental awareness, and the laws endorsing it, have forced the automotive
industry to focus on ways to reduce the vehicle weight. Lighter cars invariably mean
lower fuel consumption, resulting in reduced exhaust CO2 emission, which is a major
atmospheric pollutant.
221

Incorporating aluminium in the car fulfils this requirement in an exceptional manner.
For example, compared to traditional steels, aluminium rolled sheet for doors, bonnets
or wings can amount to a 50 % weight reduction.
The tradition of using steel and the cost of using aluminium are challenges when
introducing aluminium into the automotive sector.
222

Overview
Strong - The entire vehicle can be aluminium
Durable - Good resistance to corrosion and fatigue
Conductive - Both thermal and electrical
Non magnetic - Useful in electronics
Non toxic - Important in any material used in cars
Abundant - Adequate supply world-wide (Bauxite)
Recyclable - Saves energy, benefits the environment
Workable - Uses well understood metal working processes
Available - Aluminium’s many product forms offer design flexibility
Above all its low density and high strength means that aluminium parts weigh much
less than their equivalent steel components.
223

Different types of Aluminium alloys
Magnesium (Mg) increases strength through solid solution strengthening and
improves work hardening ability.
Manganese (Mn) increases strength through solid solution strengthening and
improving work hardening ability.
Copper (Cu) gives substantial increase in strength, permits precipitation hardening,
reduces corrosion resistance, ductility and weldability.
Silicon (Si) increases strength and ductility, in combination with magnesium produces
precipitation hardening.
Zinc (Zn) substantially increases strength, permits precipitation hardening, can cause
stress corrosion.
Iron (Fe) increases strength of pure aluminium, generally residual element.
Chromium (Cr) increases stress corrosion resistance.
Nickel (Ni) improves elevation temperature strength.
224

Different types of Aluminium alloys (Cont.)
Titanium (Ti) used as a grain-refining element, particularly in filler metals.
Zirconium (Zr) used as a grain-refining element, particularly in filler metals.
Lithium (Li) substantially increases strength and Young’s modulus, provides
precipitation hardening, decreases density.
Scandium (Sc) substantially increases strength by age hardening, grain-refining
elements particularly weld metal.
Lead (Pb) and bismuth (Bi) assist chip formation in free machining alloys.
225

Alloying element
1000 series – Commercially pure aluminium.
2000 series – Aluminium-copper alloys.
3000 series – Aluminium-manganese alloys.
4000 series – Aluminium-silicon alloys.
5000 series – Aluminium magnesium alloys.
6000 series – Aluminium-magnesium-silicon alloys.
7000 series – Aluminium-zinc-magnesium alloys.
8000 series – Other elements e.g. lithium, iron.
9000 series – No alloy group assigned.
226

Processes to be followed when repairing aluminium
The use of aluminium requires changes in certain working procedures. As aluminium is
a soft, malleable, ductile and conductive material, certain points must be observed:
The work area must be dedicated to working with aluminium materials
– free of other equipment & materials which could contaminate the aluminium.
The work area must be protected from grinding operations on steel or other materials
and include a dedicated suction unit for collecting aluminium dust.
All tools or abrasives required for operations on aluminium must only be used for this
material, as aluminium is sensitive to differences in electrical potential.
227

Safety rules
Aluminium dust must be collected separately to steel. As these two materials are
incompatible, failure to follow the basic safety rules will lead to:
– A risk of very fast corrosion caused by the electric potential created by
mixing different materials (steel in the aluminium part).
– A risk of smoldering or explosion due to the simultaneous presence of
aluminium dust and the dust of certain metals, especially steel (risk higher on
industrial sites).
Note:
This risk is minimal but must be taken into consideration.
228

Safety rules
All fixings where aluminium and steel come into contact, must be replaced if removed
during the course of repair, unless stated by manufacturer. This is due to a coating on
steel fixings being destroyed when removed.
All nuts and bolts must be torque set, this information can be found in workshop
manuals.
229

Basic hand tools can be used if exclusive to Aluminium
Mallet (wooden), Dolly, Body file, Stainless steel wire brush, Panel hammer
230

As there is a higher risk of stretching an aluminium panel than a steel panel, the panel
beating operation must be carried out carefully.
The temperature during panel beating operations can be easily checked using:
An adhesive temperature gauge.
Part no.: 77 11 219 849
A temperature indicating crayon
231
PRODUCTS RECOMMENDED FOR QUALITY
In After-Sales, repairs to aluminium must only be carried out using the products
recommended by the manufacturer.

Assess panel damage
Eradication of panel damage
232

Remove paint from damaged area
Any sound deadening or other material from the back of the panel should be removed
to help prevent stretching.
233

Important!
Before using any tools to carry out panel beating operations the surface to be worked
on needs to be heated (annealed).
This has the effect of ‘softening’ and making the area more malleable.
We need to remember failure to do this will cause the aluminium to stretch
significantly making repair very difficult. Aluminium can also fracture very easily when
worked cold.
Heating has previously been carried out by technicians using an oxy-acetylene torch.
This is not safe and it is very easy to overheat the surface causing it to melt -
Aluminium does not change colour when heated.
234

To combat both of these problems a
method of monitoring heat needs to be
used and preferably a hot air gun (some
have thermostats that can be set).
Heat the area to be worked on until the
desired temperature 110ºc is reached.
Heat gun and thermometer strip
235

A body file can be used to highlight both
high and low spots.
Reshape panel
A wooden mallet can take the place of a
steel panel hammer as this will also
reduce the likelihood of further damage
and/or stretching.
236

Note:
Cold working can be carried out on damaged areas that are no greater than 50mm in
circumference and up to 4mm in depth.
It is recommended that damage greater than this is heat treated before any panel
beating takes place.
In practice larger repairs can be completed without heating, but remember this may
conflict with a manufacture’s repair guidelines.
Great care needs to be taken as aluminium can damaged and/or stretch very easily!
237

Once your repair is at a satisfactory
level with the panels shape uniform a
body filler that is compatible with
aluminium can be used to finish.
Complete the profiling in the standard
way but remember to extract your dust
using a dedicated system.
Apply body filler
239

LESSON 8 SUMMARY – INTRODUCTION TO ALUMINIUM
Recognise how aluminium differs from
steel
Understand the advantages of using
aluminium in vehicle bodies
Recognise the different operations
used in aluminium repair
How to treat aluminium during the
repair process
240

DAY 4 – PA RT 2
B O DY F I L L E R M I X I N G &
A P P L I C AT I O N
241

WHY USE BODY FILLER?
Now we have established types of
damage and how to work with them,
let’s now think about what happens
now we have roughed out the repair.
If the repair cannot be metal finished
then a body filler will have to be used.
Remember that the surface to be filled
should be almost to the correct shape
as it is not recommended to apply body
filly with a depth greater than 4mm in
total.
242

WHO SHOULD DO THE BODY FILLER WORK?
Both body and paint technicians should have an understanding on how to mix, apply
and sand body filler (putty) and the putty and paint surface preparer should
understand the dent repair process.
This way the transition from the bodyshop to the paint shop is smoother.The putty and
paint surface preparer is not having to rework the area if the dent is not straight.
This will reduce bottle necks from too much rectification having to be done in the paint
shop because of poor preparation in the panel shop.
Body technicians will practice mixing and applying putty and putty workers will master
putty mix, application and finish techniques.
It will be a fun practice!
243

MANY TYPES OF PUTTY FOR SPECIFIC PURPOSES
244

Body fillers are available for many
different applications such as filling
Plastic, Steel, Aluminium and SMC
(sheet moulded compound).
Fillers are available from a range of
different manufacturers but will in
most cases have the same use and
application.
We shall also look at what filler is made
of and the technologies involved within
its manufacture.
We will also learn the different
application methods and how to work
with the different filler types.
TYPES OF PUTTY
245

Filler is made up of a resin which acts as
a binder to hold other pigmentations
together.
The pigmentations have until recently
been in the form of talc……the same
kind that you use in the bathroom!
Talc is what made the cured filler easier
to sand than previous fillers and is one
of the main reasons for large amounts
of dust when sanding.
The most common filler in use is known
as a lightweight polyester filler.
LIGHTWEIGHT POLYESTER FILLER (PUTTY)
246

Lightweight fillers are still not fully
waterproof and remain hygroscopic.
The definition of hygroscopic is:
readily taking up and retaining
moisture.
Typical uses are the same as
heavyweight fillers. It is also worth
noting that the glass spheres help
maintain a more consistent mixture of
resins and bulking agents throughout
the life of the product.
Note:
The glass beads are based on micro
sphere technology
LIGHTWEIGHT POLYESTER FILLER (PUTTY)
247

Two-component polyester filler used for
the filling of holes and imperfections.
Extremely lightweight body filler.
Excellent filling properties.
Flexible.
High adhesion to a steel surface.
This is the standard type of filler used
on most panel repairs, either large or
small.
POLYESTER FILLER
248

Polyester finishing stopper is suitable
for a variety of substrates.
Very smooth spreading and pinhole free
to provide the perfect substrate for
painting.
Can be used for small areas and shallow
depth filling.
Can also be applied on top of other
body fillers after they have been sanded
down to fill very small imperfections
and pin holes.
POLYESTER FINISHING STOPPER
249

Multifunction body filler can be used
for deep filling or finishing.
Excellent spreadability and sanding
properties.
Adheres directly to a variety of
substrates including.
galvanised panels and some plastics.
Uses latest resin technology for a
pinhole free very easy sanding product
even after 24 hours.
The pigments are ground to even
smaller pieces to allow for smoother
sanding and better scratch coverage,
leaving even less pinholes.
ULTRA LIGHTWEIGHT BODY FILLER
250

The catalyst (hardener) is mixed with
the body filler and speeds up the drying
process.
Hardeners contain a number of
different ingredients but the main
ingredient is Benzoyl Peroxide.
This substance will typically be 60% of
the overall hardener.
Hardener is coloured so the technician
can clearly see if the product has been
mixed thoroughly.
Different coloured hardeners will come
with different coloured body fillers.
CATALYTIC HARDENERS
251

Filler should be mixed on a clean non-
absorbent surface.
This example highlights one
manufacturers solution.
Clean solution for mixing filler pastes
and materials.
Reduces pin-holing.
Surface avoids soaking up resins and
solvents.
PUTTY APPLICATION BOARDS
252

Other methods of application can be used
such as these steel spreaders.
PUTTY APPLICATORS
Plastic applicators have a flat leading
edge to give an even finish and control
over the depth of the filler product.
253

Ideal for flexible substrates such as
bumpers, SMC & most plastics.
The product shown can be used to fill
over the manufactures products.
Pinhole free polyester filler that is fast
drying and easy sanding.
Fills scratches and scuffs or can be used
to finish a repaired area.
HIGH ADHESION BODY FILLER FOR PLASTICS
254

APPLICATION OF BODY FILLER
Remember!
The use of body fillers should not replace good repair methods.
Repairing still takes place prior to the application of fillers – maximum depth 4mm.
The application of filler can be affected by the ambient temperature. If it is outside of
the filler’s recommended working range it may not cure properly.
If the temperature is below what is recommended it may take an excessive time to
cure. Do not be tempted to add more hardener.
If it is warm you may have to work quickly so that the filler does not start to cure
before you apply it.
255

If more than the recommended amount
of hardener is added filler is said to be
‘over activated’.
Because filler and hardener are
designed to be mixed in a specific ratio
and a chemical reaction takes place, the
excess hardener may not react with the
filler and be left in a‘raw state’.
An excess of hardener may lead to
bleed through.
256

Before the repair is‘filled’ ensure that
you have carried out repairs to the
panel first using traditional panel
beating methods.
ie: using a hammer, dolly, spoon,
bumping blade, shrinking.
257

Mix and apply putty
Clean the surface Remove paint from
the repair area
Mixing body filler
Apply putty
258

MIXING OF BODY FILLER
It is best to mix filler on a flat surface that is clean and non porous.
Use an Onion board for example.
If a surface such as cardboard is used it will tend to allow air into the mixture which not
only affects curing time but may also leave pin holes.
259

Generally filler is mixed with to a ratio of 2% hardener.
To put another way; this is a golf ball size amount of filler to a pea size amount of
hardener.
Adding hardener directly to the filler may cause uneven hardening as the reaction is
taking place straight away.
260

Scoop up the hardener and then add it to the filler and begin to mix.
261

Start to apply the filler in even strokes.
Do not spend time going back over the same area otherwise the filler will be lifted
away. Clean the applicator between strokes.
262

Apply the filler in even strokes. Do not spend time going back over the same area
otherwise the filler will be lifted away. Clean the applicator between strokes.
263

Keep the filler within the primer area away from paint edge
Use special tool for spreading the filler evenly
264

Filler can be applied up to 4mm thick
Allow to cure with Infrared lamp for 5 minutes
265

FINISH OF BODY FILLER
Once putty is sanded check with the
palm opposite to your writing hand
(more sensitive).
Check for imperfections such as
pinholes.
You may need to apply more or use a
stopper.
Finish before applying putty should be
at least P80 Grit free-cut paper.
Feathering before going to paint shop
for priming is P120 Grit free-cut.
266

BODY FILLER – BASIC BUT IMPORTANT POINTS
Use Putty (Body Filler) straight after
throughly mixing with hardener.
Make sure you mix the hardener with
the filler well.
Make sure to keep sealing the can and
the hardener tube after use.
Make sure to use DRY sanding - Wet
sanding is not acceptable.
Do not mix more than you need – it all
costs money and disposing of surplus
wastage is also not environmentally
friendly.
267

LESSON 9 SUMMARY – MIX & APPLYING PUTTY
Understand the types of tools and
materials used for mixing and applying
putty
mixing and applying putty
Understand the methods of sanding
and shaping the putty
269
LET’S PRACTICE

DAY 4 – PA RT 3
A N T I - CO R R O S I O N S E A L I N G
270

POINTS ON CORROSION
Once bare metal on a body panel is
exposed to the atmosphere the
corrosion process starts.
In a humid climate body panels can
start corroding in 4 hours.
Be sure to treat bare metal if left
overnight, as otherwise major rust
problems will happen within 12
months.
Seam sealers need to be applied before
the repairs are painted.
Sound deadening pads will be fitted
later.
271

EQUIPMENT TO USE FOR SEAM SEALING AND ANTI-RUST
ANTI-RUST
Sealer Guns & attachments
Sealers
272

A. Sound Deadening Pads
B. Rust Proofing Inner Panels
C. Underbody Sealant
EQUIPMENT TO USE FOR SEALING AND ANTI RUST
A B C
273

SEALING UNDER HOODS AND AROUND HINGES
Effort should be made to replicate the GM methods of sealing
274

AROUND HATCHES AND HINGES
Access GM technical data on where the panels should be sealed
275

INNERS OF DOORS AND HINGES
276

Your repair should now be completed and ready for the paint shop - well done!
ANTI-CORROSION SEALING
278

LESSON 10 SUMMARY – SEALING OF BODY COMPONENTS
applying anti-corrosion sealants to
body panels
Understand the methods used in
applying anti-corrosion sealants
280

INTRODUCTIONDAY 5
CO U R S E S U M M A RY A N D
T E ST I N G
282

NON STRUCTURAL COURSE SUMMARY
You have reached the end of this course. You should now have:
Underpinning knowledge of the
Health and Safety aspects of working
in a bodyshop
A broad understanding of the types of
tools used for non-structural repairs
Knowledge on how metals are affected
by deformation and how it applies to a
bodyshop
An understanding of how to repair
metals using various panel repair
techniques including shrinking,
roughing out and denting
283

Knowledge of how to finish the repair
of a dented panel by either metal
finishing or putty application
Knowledge of where to apply anti-
corrosion agents on new body panels
Practical experience in all of the lessons
learnt in the classroom
NON STRUCTURAL COURSE SUMMARY (CONT.)
284

PRE-TEST DISCUSSION
We are going to write down on the
walls what we have learnt through
joint discussion.
One person will be selected to write
down topics on block paper (one page
per lesson) from group discussion
regarding the key points from each
lesson summary.
The pages will then be placed on the
walls around the testing room.
Technicians can use their notes and
handouts as well as the notes on the
walls to take the test.
The written test will be on a strict time
limit so practical testing can be finished
on the day.
285

LESSON 1 SUMMARY – HEALTH AND SAFETY
During the lesson we covered how to:
Be aware of your safety environment
and how you can effect others
Protect yourself from harmful
situations
Understand that some health issues
are caused by long term exposure
Know what is the right safety
equipment to use
286

Know what to do in case of fire
Identify signage and protect yourself in
that environment
Understand why you need to work in a
clean workshop
LESSON 1 SUMMARY – HEALTH AND SAFETY (CONT.)
287

LESSON 2 SUMMARY – TOOLS & EQUIPMENT
Understanding the types of tools used
in fro non structural work on a
bodyshop
Be able to identify these tools
Have knowledge of certain safety
aspects of the use of the tools
288

LESSON 3 SUMMARY – METAL CHARACTERISTICS
Understand characteristics of metals in
non structural repair
Understand how this engineering
applies to body repair techniques
Use this knowledge to perform dent
repairs in a logical way
REMEMBER THIS!
289

LESSON 4 SUMMARY – SHRINKING
shrinking
shrinking
Understand the purpose of shrinking
HOW DID YOU GO?
290

LESSON 5 SUMMARY – ROUGHING OUT
roughing
roughing out
Understand the purpose of roughing
out
HOW DID YOU GO?
291

LESSON 6 SUMMARY – DENT PULLING
dent pulling
Understand the methods used for dent
pulling
Understand the purpose of dent
pulling and how different ways can
achieve the same result
HOW DID YOU GO?
292

LESSON 7 SUMMARY – BODY FILING & METAL FINISHING
metal finishing
metal finishing
Understand the purpose of metal
finishing
HOW DID YOU GO?
293

LESSON 8 SUMMARY – REPAIRING ALUMINIUM
Recognise how aluminium differs from
steel
Understand the advantages of using
aluminium in vehicle bodies
Recognise the different operations
used in aluminium repair
How to treat aluminium during the
repair process
HOW DID YOU GO?
294

LESSON 9 SUMMARY – APPLICATION OF BODY FILLER
Understand the types of tools and
materials used for mixing and applying
putty
mixing and applying putty
HOW DID YOU GO?
295

LESSON 10 SUMMARY – ANTI-CORROSION SEALING
applying ant-corrosion chemicals to
body panels
Understand the methods used in
applying anti-corrosives
HOW DID YOU GO?
296

WRITTEN TEST
Questions are Multiple Choice covering
all the topics learnt.
As soon as you have completed the
exam please raise your hand.
No talking to eachother during the test.
You have 2 hours to complete the test.
Your test results will be scored with the
following criteria:
Good
OK
Keep Trying
297

PRACTICAL TEST
Most of the practical testing will have
been completed during the week
however you will be asked a series of
questions in the work area to test your
knowledge when applying yourself.
Specific topics for practical testing on
the final day will be dependant on the
level of skill over the course of the
week.
GOOD LUCK!
298

END OF THE NON-STRUCTURAL COURSE
THANK YOU
299

GM Non-Structural Training Course 5 days

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