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SUBARU Body Repair Technical Skills Handbook

1. ccccccsseeeccsesseeeceeeseeeeceeeeeeseaseeeeeeaaeeseesaseeseseseeseens 5 2 Hammering and pulling EE 6 3 M ss ging panels serais Aaa EEEE aaa aR EAN 6 4 Pulling points lines and Re E EE 7 5 Panel beating tools machines and materials cccccceceeeeeceeeeeeeeeeeeeeeeeceneseeeseanseanesaeeseeessanesanesenessnesaes 7 Si Elo tte 7 CV SUG IVE IOG E E E EEEE E E E E EE E A E E 9 S MP NUN ke 9 4 Towers chain pullers hydraulic ramS ees eege ENEE EES dEEAESEE 10 5 Other EE EE 11 6 Beating using a hammer and dolly cece ceccceeeeeeee esse eee eeeaeeeaeeeeeeesaeeeaeeeaeeeeanesaaesaeaeseneseeesaeasaaesanessnnges 13 1 Principles of hammer and dolly repair tee 13 2 On dolly and off dolly hammering EE 14 7 Pulling using a stud ease hice cetenes tes set sees te aes teat ene ano eeeneeee anes cect eeee sects acecsaessnecteeaeuescentaieescnce 15 Si CU NG Ce ie S gt ae E A ned saannessanant sadantatauaassieeasuuaat tings beneqasaeaaens sare E 15 SCT Kette Te Ee EE 16 3 In combination with hammering E 17 8 Identifying damage patterns and repair work ENEE ENER ENER ENKER EN ENER ENEE ennen 17 1 Identifying damage E EE 17 2 Wide mild deformiatiOn essere ce su nedepnitcpenadhquer nionee aa e a ra a Ea EEEa aaran Eai 17 3 Small sharp angled deformation cccccccsssececcsseecceeeeeeeeceaueeeeceaseeeceaaeeeeesaseesseaasessessaeesesauseessssageees 18 4 Long thin CUT Oi dU ON RE 19 Ate 19 9 Shrinking sheetme
2. ccccccceceeeeeeeceeeeeeeeecaaeeeaaeeesaneesaaeesaaeesaaassaaeseasesaaneesanessanessaeesas 3 1 Damage prone e ET 3 2 Easily overlooked Be Eete Cte LE 4 3 Arrangement of Opening parts and body damage l cccccsseeceessseecceeseeseceueeeeesauseeeeseaaeeeeesaeeeesseaseeseeas 4 4 Front end collision and damage c cssssccccssseceeceuseeeccsaseeecceeeesesuseeecsuaseeeeeseeesessuseeesseageeesssageeesseaseeseeas 5 5 SUS c llision and un EE 5 6 Back end collision and damnage sgacsssapcanconesascnctasnaiecasanrnensaaantaaoraantoyaaysuenenssananeaedteatiaaanns ons EEE a aai 5 7 Damage caused by secondary iMpact eebe geen 5 3 ANNO to outer panels osere aa a a a aaa E Aaaa 6 Damage analvesl Zi 2 1 Damage diagnosis 1 Circumstances of accident Check information concerning the circumstances surrounding the accident The 5 W and 1 H approach ts the best When Time the accident occurred Where Site and road conditions Who Driver passengers What Another car or object Why Cause of the accident How situation at the time of the accident speed relative speed load impact site angle etc 2 Order of diagnosis First check the damage in a light area where there is a hoist jack lamp measuring tape etc Start with the whole vehicle and then look at individual sites Overall appearance Walk around the vehicle Look for entry sites and around the damage If there is more than one site check the or
3. 10 Safety precautions 1 Welding arc and sputters Arc welding produces a strong arc that contains ultraviolet rays Place the workpiece so that you don t have to look directly into the arc Wear welding gloves and do not expose skin directly including the arms Exposed skin can be burnt by not only the arc but also by weld sputters Make sure work clothing is buttoned or zipped 2 Fire Since welding generates sparks make sure there are no hazardous items like gasoline or thinner in the work area 3 Gas cylinder The gas inside the cylinder is liquefied and compressed Use a cylinder that is not damaged do not subject it to any impact and avoid sudden temperature rises such as exposing it to direct sunlight Handle carefully when replacing or shifting Handling of welding equipment 11 4 Oxyacetylene welder Oxyacetylene welders were once commonly used However this type of welding is no longer used in body repair due to distortion caused by heat the occurrence of rust after welding and insufficient strength Shrinking is also mainly carried out using electrodes Today this is limited to heating or cutting panels no longer in use Mi Gas welder components Oxygen cylinder The cylinder contains oxygen compressed to approximately Oxygen valve for cutting 2 Torch head 150 kg cm2 The cylinder is black Owgdensibe e Oxygen hose plug Acetylene cylinder Acetylene is dangerous It is stored in a cylinder
4. Cut the part where a new part is not used Approx 50 mm Cut ye 3 E Body side ZE Reinforced Reinforced panel Approx panel Remove the paint film and 50 mm paste a spot welding sealer Replacement of welded panels 11 4 2 Order for replacing welded panels 1 Removal of damaged sections 1 When to remove parts Unlike a bolted on panel once a welded panel is fit ted its position cannot be adjusted Therefore this work needs to be done carefully The welding of new panels should be done in associa tion with body alignment If the measurements of un derframe parts can be corrected during alignment re move panels that will be replaced with new panels However if this is done too soon the dispersion of force to surrounding parts during the remaining repair work will not go well and could take longer Conversely if you wait until all body repairs have been completed it will take longer The basic rule of thumb is to remove parts once the measurements of key points for welded parts have been corrected or when they align perfectly with the measurements of the adjoining panels 2 Rough cuts Decide on the sites to be cut out and make a rough cut Since panels that are to be removed don t have to be re paired if necessary to make repair work more efficient cut out these sites before the panels are removed When make a rough cut be careful not to cut wire har nesses and tubing on the underside or in p
5. Make a visual check of the weld sites to see wheth er the welds have adequate strength Use a disc sander or belt sander to smooth the surface of MIG plug welds and butt weld sites Be careful not to grind too much Because the heat generated through MIG weld ing can cause distortion if necessary repair using hammering Deburr spot welds using a sander also Then apply a sealer antirust agent or foaming agent Apply more rustproofing than would be used for a new vehicle This is because welding makes metal prone to rusting Replacement of welded panels 11 9 3 Bonded panels 1 Structural adhesives There are two methods for bonding panels using a structural adhesive using only an adhesive and com bining an adhesive and welder The former method is called panel bonding while the second is called weld bonding Using an adhesive has the following advantages stress is evened out welded parts do not deform they have excellent water tightness and air tightness and it is easy to join different materials The disadvantages are that thermal resistance and repeat bonding are not very good and hardening takes time Bonding provides similar or superior strength to spot welding because unlike spot welding where spots are welded it is the surface that is joined 2 Bonding methods When cutting out and making a patch there are a number of methods depending on the repair site and strength The two mai
6. as a conduit for electricity and gas and is exposed to high tempera tures the torch is the most susceptible to wear of all MIG welding S Switch Nozzle components 6 Gas cylinder The abbreviation MIG stands for Metal Inert Gas which is used to form a shield around the weld site This prevents rust minimal gas is used and it produces a tidy finish However argon an inert gas is expensive and though it is used for aluminum alloys an activated gas metal active gas or a gas made up of a mixture of carbon dioxide and argon is used for nor mal sheetmetal Since the majority of welders use carbon dioxide gas it is more correct to call this welding MAG metal active gas welding However the term MIG welding is commonly used for this method This commonly used carbon dioxide gas has a specific gravity of 1 529 and with a melting point of 56 6 C It is a gas at room tem perature Carbon dioxide gas is colorless transparent tasteless and odorless The gas cylinder should always be upright Use a belt or chain to stabilize it and prevent it from tipping over When exchanging the cylinder make sure it does not receive an impact Gas cylinders are color coded to allow immediate identification of the contents Carbon dioxide cylinders are green and argon gas cyl inders are grey Cylinders are fitted with a gas regulator Lower the cylinder pressure 2 3 kg cm and adjust the gas flow rate so that it is appropri
7. 1 Reinforced glass Reinforced glass is used in doors and for the rear window It is made by heating sheet glass to around 600 C and then cooling it rapidly Glass breaks due to tension upon impact But because with reinforced glass high compression force is locked inside it is extremely hard to break It has between three to five times the impact resistance of ordinary glass It can also withstand huge differences in temperature If it does break it breaks into many round fragments There is also reinforced glass that will maintain a certain field of vision even when broken 2 Laminated glass The use of laminated glass for windshields has been mandatory since 1987 Laminated glass has a thin robust plastic membrane sandwiched between two sheets of glass When broken it does not fragment but stays in one piece allowing visibility It also makes it difficult for objects to penetrate the windshield Laminated glass with a thick layer in the middle with high impact resistance is called HRP laminated glass Reinforced glass Safety glass Laminated glass Compression stress gt g Compression stress against the impact is sealed in 2 5mm plate glass o 75 mm intermediate membrane 2 5 mm plate glass The intermediate membrane made of polyvinyl butyrate is sandwiched between two sheets of glass Body materials 3 17 2 Special glass It is common for additional functions to b
8. Determining the area of the damage and the type of deformation can affect repair efficiency and time The reason is that by first repairing directly damaged parts where plastic deformation has occurred the elastic deformation in indirectly damaged areas will largely be corrected This means that restoration will take longer if you repair parts with indirect damage first Removal and fitting of parts 8 1 Chapter 8 Removal and fitting of parts Contents Ds RINE TO ONG Geet 2 DIPS OF FANG e te E 2 2 JIGS te HEN 2 GIE Te Ta e M 3 CLET aS ee 3 60 Bo e216 Fa 6 tee 3 6 OW to handle hand e e EE 4 2 Power 0 ONS sec gesreceniee ceciea E E E E uddnemertuinnsneesnabedincvendiess 4 1 Removal and fitting tools EE 4 21 Daling and Jogging Ee LEE 5 02 NEL DG SC IN eeh 5 3 Removal and fitting pointers isien erect ateciaea eat ciaetsd ae ana a aiaa da a aha iaaea aE daakini eaaa Ea 6 Tires e Run EE 6 EZ ee Ei Ee Re E 6 4 Electrical components Wire harness cccscceeeeeeeeseeeeeceeecaeeceeseeesanesaeseeesaneeaesaeeseaesaasaeeseeeeaaeeeesaneseaeseesons 9 SW AT el oF e ann ae rer ee ee ee ee een ee ee eer oe 10 6 lyp s ge UE 11 Removal and fitting of parts 8 2 1 Hand tools A variety of tools are used in vehicle repair Below is an explanation of general purpose tools such as those used for disassembly assembly and cutting 1 Types of hand tools Hand tools are tools that don t use electricity or compr
9. Select the shape that matches the panel surface that is to be repaired n 7 Pulling using a stud 1 Pulling tools 1 Making something to gain leverage External panel repair 5 15 When pulling a more or less flat panel you need something to grab hold of There are three methods Weld something on to the panel surface Make a hole in the panel or Use a tool that doesn t require something to pull on 2 Welding on something to gain leverage Washers stud pins thin sheetmetal etc are com mon examples of things welded on A dedicated stud welder is used for washers and stud pins The washer stud is put in one of the electrodes while the other electrode is earthed Dedicated or universal slide hammers can be used to attach the washer and stud but because with a stud there must be a struc ture to hold the pin washers that can be hooked into a hole are more versatile A number of washers or studs can also be welded in a row Connect them and apply force to the larger area Although there are some special plate shaped wash ers they are usually used on the cut ends of assem bled panels They are attached using a MIG weld or soldering machine They are particularly useful when a lot of force is required A clamp is attached and they are pulled using a large slide hammer or a tow er and chain puller 3 Making a hole in the panel RN Attaching washers Attaching studs This can be done
10. The surfaces of panels to which putty is applied have a variety of contours Use the most appropriate applicator for the surface Choose a hard applicator for a flat surface A soft applicator is suitable for slightly curved surfaces For a steep curve the filler won t follow the crown unless an elastic applicator like a rubber applicator is used When applying filler to a curve it tends to be thick on the edges and thinner in the center If soread too thickly sanding will take time If spread too thinly filler will have to be applied again after sanding Conversely since reverse crowns are hard to sand apply a minimum amount For press lines don t apply all at once Check the shape and using the line as a border apply putty twice once above the line and once below the line Attach masking tape next to the line on the upper side of the area being filled When you have applied putty be low peel off the tape and apply putty to the top If the putty is dry you can also attach masking tape on the lower side W How to apply putty Folding Building up Smoothing 45 60 First apply the putty very thinly Apply the putty repeatedly Finally lay down the applicator and fold as necessary and smooth the surface W Technique for applying putty Shapes of the damaged sections and Applying putty at press lines applicator handling Q GEN GH A e BaT Ge Li VW KE SE Applicator handling a the tig
11. You can indicate here Combined force Repair of the underframe 9 19 2 Principle of action and counteraction When force is applied to an object the same Action and counter action amount of force is produced in the opposite di rection For example if a drum on the ground is Counter action pushed with a force of 10N it will produce a counter force of 10N in the drum in the opposite direction This force functions as a kicking force against the ground by the person who is pushing the drum Therefore when the ground where you kick is slip pery like ice and thus the counter force is not able to be transmitted to the ground the drum won t move at all no matter how hard it is pushed The initial pushing force is called action and the repel lent force is called counteraction Action Counter action Rockets and jet planes fly in the sky because of the force of the counteraction in the opposite direction to the force injected by burning fuel When pulling force is applied in a pulling direction to a body that is anchored to an alignment system the body will produce a reaction force in a pushing direction toward the alignment system and the alignment system will produce a similar reaction force in a pushing direction toward the floor or bench Accordingly force more than that which can be sustained by the anchoring system cannot be applied to the body Also since force is also ap plied to the body where it is attached to the a
12. 4 5 Frame repairs Set up body repair equipment Also measure the dimensions of each site while referring to drawings of body dimensions and check the extent of the damage Using your measurements pull out the necessary amount of the damaged site and restore it to its original dimensions Even if there are welded panels that need replacing leave them and carry on with repairing the car body This body repair work is known as body alignment 6 Replacing welded parts When each part has been restored to its original dimensions cut out the welded parts that are to be replaced Remove by cutting along the original weld lines Tack new panels to the body and make tiny adjustments to the body by pulling using repair equipment Also at tach external parts and check the gaps between the panels Weld the replacement parts when they fit neatly to the body This completes repair work done using body repair equipment 7 Panel beating exterior panels Damaged panels that are not replaced are repaired by removing surface paint and then using methods such as beating with a hammer or pulling using welded washers or studs pins Depending on the site and extent of the damage bolt on parts may be removed and then repaired 8 Painting The painting process consists of two main parts the primer coat and top coat Tools used and the order of work for the primer process which follows body and panel repair differs from work shop to workshop Basica
13. 5 Handling air tools Daily maintenance of air tools is vital so that they can be used when required Use air at the prescribed pressure for each tool Do not use tools for any other purpose Use clean air Clean check and oil each tool as appropriate after use and at the end of the working day 6 Maintaining quality Maintaining quality is based on the established standard process and is achieved by repairers with recognized skills making repairs in accordance with the various manuals for devices equipment and materials As a result precision is further enhanced by getting a third party to check quality based on a checklist Established standard process Outstanding facilities equipment and materials Qualified engineers Quality inspection 13 6 Appendices 1 Appendices Contents 1 Auto body repair workshop equipment ccccccceceeeeeeeeeeeeeeeeeseeesaneeaesaaesaneeaaseaesaaesaasaeseesaaseneseneseneaaesags 2 Sie Ter 2 2 AG AGS CK EEN 2 US IR EENEG 2 CA POWER SUID OI e EE 3 5 Headlamp tester E 3 C6 ge E let te 3 7 D usi colection SYSTE EE 4 WEE geess d KA ER EC E 5 OU BOY e ue UN 5 EEN DOG een 5 3 SSOhVICE Wa EH EECH e E EE 5 Appendices 2 1 Auto body repair workshop equipment The following are the main pieces of equipment and systems required by an auto body repair workshop equipment 1 Hoist A hoist raises a vehicle using an electric mot
14. Pushing Push the repaired part with your fingers The biggest dent will be the center of the stretching If the stretching is severe it will make a rumbling noise If all parts feel the same when pushed it means there is no stretching If another site deforms when you push it means that the part that deformed has stretched External panel repair 5 22 3 Principles of shrinking Metal expands when heated and shrinks when cooled Shrinking is applying this principle to sheetmetal that has stretched When stretched metal is heated the hot sheetmetal will try to expand but it won t be able to because the sur rounding metal is at room temperature Expansion will concentrate in the stretched thinned area If it is instantly cooled at this point the stretched surplus area will lock up While the metal is hot beat the perimeter of the stretched area as if shifting the sheetmetal to the center If the perimeter of the stretched area is large repeat the same action a number of times Shrinking should be done quickly When heating heat as small an area as possible to a high temperature If it takes too long and the heated area widens the whole area will bulge and render the task meaningless When cooling quickly cool the hot area while it is still hot If it is cooled slowly the sheetmetal that has collected in the stretched area will widen and you will be back where you started W Principles of shrinking Suppose there is an iron rod
15. Setting up bench type equipment eege 10 4 Anchoring the damaged vehicle horizontally cseecccccesseeeeceessececeeueeeeccauseeeeueaseeseseaeeesesauseessssaaeees 11 5 Measuring the e e UE 11 1 The purpose of measuring NEE 11 2 Types of measuring devices and characteristics sesssessnreurrrrnrnnunrnnrnrrrnnrernnnrnnnnnnnnnennnnrnnnennnernnnne nne 12 SLO KG at Dody EE 15 6 Body alignment E 16 1 Accident entry and pulling E 16 2 Types of pulling equipment and characteristics siuccssioscsnccosdeactsaasiactnaicassenasaaactdeetaneavuntatemuansarsineeuiatauaeas 17 3 Three elements of force EE 18 aD E 21 EEPOS roer E R a a a E N G 24 Repair of the underframe 9 2 1 Order for inner panel and underframe repairs Body adjustment and alignment equip ment is used when repairing damage to the underframe The basic order when using this equipment is to fix set measure repair measure replace welded parts and unfasten reset The work returns the vehicle to its original di mensions By repeated repairs and measure ments the original dimensions of the frame are gradually restored Leave structural parts that are scheduled to be replaced on until you have obtained the measurements you need When the dimensions are correct unfasten the vehicle from the adjustment and alignment equipment after the welded panels have been replaced Work procedure Anchoring the vehicle on the repair equipment Meas
16. both sides are zinc plated Body materials 3 8 3 High tension steel Sheetmetal usually has a tensile strength of between 275 to 294 MPa 28 30 kg mm Sheetmetal that has a much higher tensile strength is called high tension steel It has a tensile strength of between 390 to 490 MPa approx 40 50 kg mm or higher High tension steel with a strength of 980 MPa 100 kg mm is not unusual Sheets with a strength of 780 MPa or higher are called ultra high tension steel High tension steel is made by adding minute quantities of other elements to standard sheetmetal There are various types depending on the elements and production methods used 1 Solid solution strengthened sheetmetal The sheetmetal is strengthened by adding carbon C silicon Si manganese Mn phosphorus P etc 2 Precipitation strengthened sheetmetal Titanium Ti niobium Nb vanadium V molybdenum Mo etc are bound to carbon C and nitrogen N and added as minute elements to strengthen steel 3 Compound structure sheetmetal This is also called dual phase sheetmetal The steel is strengthened by using heat treatment to alter the internal structure When temperatures of above 700 800 C are applied to precipitation strengthened and compound structure sheetmetal the internal structure alters and strength is reduced It has to be heated to correct this deformation The adoption of high tensile sheetmetal has increased since around t
17. suspension and parts in the way of taking a linear distance mea surement between two points W Linear distance measurements and plane projection measurements Even with the dimension between the same measurement criteria positions its value may differ lt gt Plane projection measurements according to measurement methods lt Linear distance measurements nar NG rig Virtual measurement plane In parallel with the central line of the body 3 Obtaining accurate measurements Most of the body is symmetrical but there are some areas that are asymmetrical Although it is difficult to know right from left in the underbody basically these are described from the point of view of looking down on the vehicle from above Consequently when taking measurements under a vehicle be aware that right and left are reversed Figures will also be incorrect if linear distance measurements and plane projection measurements are confused When measuring the same place it is often shorter to take plane projection measurements rather than linear distance measurements Since a vehicle s reference points are surprisingly hard to find check using diagrams in the body manual Mea sure from the center of a hole 6 Body alignment 1 Accident entry and pulling It is often said that in order to repair a damaged body all you have to do is apply the same amount of force in the opposite direction to the impact that occurred In fac
18. the sites of the spot welds should be different from the sites on the old panel 4 Preparation for welding Cover the surrounding panels and glass with weld protec Wi Protective sheet tion sheets so that they are not marked by sputters or sparks during welding When spot welding use a part of an old panel or a piece cut off the new panel to test weld using the same material and panel thickness Check the nugget shape and size and strength of the test piece Replacement of welded panels 11 8 5 Tack welding Weld not from the edge inward but weld first at key points leaving a space in between Remove the weld clamps when the panel stops moving Check reference measurements and arrangement If there are no problems complete the welding Key points are corners and sites where the shape changes For long parts key points are evenly spaced points Weld alternately rather than in one direction 6 Welding Fill in the spaces between the key points As with sites where the panel has been cut out to be patched once welds have been made at intervals weld the spaces in between The various spot welder arms and air clamps can be used effectively for different repair sites The basic rule is to use a MIG welder for any sites where spot welding is not possible Use spot and MIG welding as appropriate 7 After treatment After welding check the various measurements Also check to see whether welding has caused any distortion
19. a joggle slight step on the side of the replacement part and glue it to 40 mm backing the body using adhesive Riveted after Use a flanging tool that can also be used on crowns and corners fixing with vice After clamping the cut surface with a special vice fasten using rivets Standard panel replacement Examples Roof panel door outer panel Advantage Fewer weld points 50 mm interval Replacement of welded panels 11 10 Repairing aluminum alloy and plastic panels 12 1 Chapter 12 Repairing aluminum alloy and plastic panels Contents 1 Aluminum ECHT EEN 2 SE E EE 2 ZED ge ig EE 2 US CCU a E E varnr je sscaueanio ae neues E A E E 2 AE e tu e WEE 2 5 ETS EE E EE 3 2 Repairing plastic panels ccccccccsccceeceeeceeeeeeeeeesanecaeseeeseaesaaeaeeseeeeaeeeeseeesaesaeseaesaesanseeeseaesaneseeseeesanesenses 4 D NDO CLEAN te EE 4 2 Ma jor damage Sieger enee Eege 4 31 Cracks and Wee EE 5 Repairing aluminum alloy and plastic panels 12 2 1 Aluminum alloys In Subaru vehicle bodies aluminum alloys are used in the Mi The hood of the first Legacy BP BL model was made from aluminum alloy hood and the trunk lid 1 Sanding Aluminum alloys possess different properties to steel and though the same basic body repair methods are used several precautions are required First because the surface is soft deep sanding marks are easily made When removing paint use paper with a fin
20. a supplied assembly or by removing one section and replacing that section with a patch 1 Assembly replacement This method involves replacement using a supplied panel and is used for parts such as the radiator panel front wheel apron rear skirt and roof panel 2 Patch replacement This is when the damaged area is cut out and replaced with a patch In general if a reinforcement has a complex construction rather than replacing the whole reinforcement a sec tion is cut out and replaced with a patch This is a more efficient method Accordingly the rear quarters side sills and center pillars can be easily replaced using this method In addition to showing structure and strength a body manual also shows the best sites for cutting and the number of weld points The basic rule of thumb is to cut out leaving a 50 100 mm margin to a panel corner or welded section Patches are best used on sites where there are no reinforcements on the under side and the length of patch welding is kept to a minimum When replacing both the inner and outer panel of a pouch shaped part like a pillar stagger the cuts of the inner and outer panel by 30 50 mm Leave inner panels on the body side long and shorten upper outer panels Outer pillar _ 30 50 mm f i Inner pillar Replacement of welded panels 11 3 1 Joining Butt welds are often used when replacing parts that have been cut out MIG weld the gap between the new cut panel an
21. a triangular shape like that seen in steel bridges In a truss structure the contact points are sliding joints Sliding joints are joints that move and slide and reinforced braces are inserted on the diagonal to ensure Safety This creates triangular layers like those in steel bridges As a two dimensional flat surface when strong force is applied from above the four corners not only deform outward on the rigid joints of the rigid structure but the right and left members also deform However in a truss structure that is connected with sliding joints only the upper members deform and absorb the force The body of a vehicle is not a closed external wall like an aircraft with a shell structure as the underframe is made up of a combination of panels with many opening parts The passenger compartment in the middle has a rigid structure as well as a shell structure in which the entire frame can distribute the absorption of external force The front and the rear each have a rigid structure and building on top of this forms the body s chassis unitized structure W Rigid structure W Truss construction Structure assembled by fixing rigid joints members Structure assembled flexible joints so that members can rotate Example Buildings Example Steel bridges W vehicle body is a series of rigid structures Body construction H 5 4 Features of the crash safety body A vehicle body does not only have to be strong but when it receive
22. alignment equipment appeared Little was written about this so details remain unclear We do know however that the forerunner of today s jig type equipment was developed in France in the 1950s It is thought that the owner of a car repair workshop developed it by making modifications in the course of carrying out daily repair work The floor type Blackhawk Korek system was introduced to Japan from the United States in the early 1970s Mean while domestically produced floor type auto poles appeared one after the other This type of equipment most likely became widely adopted due to demand for more efficient repairs accompanying the sudden rise in vehicle ownership This was followed by an increase in equipment imported from Europe and elsewhere as well as the development of improved models in Japan By the 1980s they had been introduced to a great many vehicle repair workshops This is also when there was an increase in equipment that was solely used for anchoring vehicles as well as a variety of related equipment such as measuring equipment Today most main types of overseas equipment are imported to Japan and along with domestically made equip ment both are used taking advantage of the benefits particular to each system 2 Types and characteristics 1 Criteria for body adjustment and alignment equipment Equipment must use huge force to pull the deformed underframe while the vehicle is braced so that it won t move and must be able to
23. are underbody clamps generally used at the front and rear right and left sides of the side sills that anchor the body and panel clamps used on damaged sites and for additional anchoring Hydraulic rams have been mentioned earlier in the section on repairing outer panels A hydraulic ram is a must because it can be used universally from a tower used for making repairs through to a power unit that pulls chains and a tool that does auxiliary pushing and pulling using attachments There are also chain pullers chain blocks that can be used to pull These are used when pulling systems are too strong and when repairing minor damage They can also be used for auxiliary anchoring Measuring systems are part of body use of attachments systems and are mainly used on the underbody There is also the tram gauge which is used to measure lengths of certain parts More detail on various devices and instruments is included in a later chapter 3 Anchoring the body 1 The role of anchoring Pulling force cannot be used effectively unless the vehicle body is firmly anchored The anchored parts receive the same force used in the pulling process If a low strength area is anchored when strong force is applied the anchored part will either deform or disintegrate Even for strong areas the right site must be chosen otherwise moment caused upon the application of force may result in the application of force in a different direction Not only will this slow down r
24. body repair equipment measuring pulling Basic repair of underframe of the inner plate Application of repair equipment Removal welding method of welded parts Replacement parts Judging whether to replace security parts Welding point bolt on parts Work method and man hour Linking with painting process Restoring the surface Restoring painted colors Maintaining the quality of the paint film Check the construction Appearance Wheel alignment Wiring inside the engine room Water leak Operation driving Repair procedures 4 3 2 Damage analysis Analyze the circumstances surrounding the cause of the damage before deciding on the order of repair tasks e Where there has been an accident this includes the shape and rigidity of the object the vehicle crashed into relative speed angle etc e Impact entry site and direction This information is used for considering the extent of the damage and the direction in which to pull out the dam aged part Measure the extent of the damage and amount of deformation 3 Preparation Draw up a plan based on damage analysis information 1 Decide the order of tasks The general method is to repair the underbody and work upwards to the upper body Where a car is damaged in a longitudinal direction up to the passenger compartment the general rule is to take precise measurements starting with the passenger compartment and working out to the front or the rear 2 Deci
25. by pulling on a hook shaped tool hooked into the hole or using the tip of a slide hammer as a drill to make a hole which is then pulled Although this is an easy way of getting something to hold on the area around the hole deforms needlessly and this takes time to repair Also if a hole is not filled adequately afterward it may cause rust and sometimes the putty doesn t adhere properly It s not suitable for areas where you can see the rear surface It also gives the car owner a bad impression Holes were the common method used before pulling using studs began to be adopted in 1975 This method is hardly ever used today External panel repair 5 16 4 Tools that don t require leverage A suction puller that uses the power of a suction cup is a good example of this type of tool Other pulling methods include using a solder shaped like a hook or attaching a plastic rod that has been softened at high temperature The stud puller mentioned earlier is a tool that uses this method The tip adheres to the panel 2 Panel pulling steps The basic order of steps for pulling a panel is shown as follows though this can differ depending on the state of the damage and the tools that are used 1 Check the damage Ascertain the scope of the damage its relationship to other sections the severity of the damage cause etc Mark the damaged section if necessary 2 Remove parts Remove pinstripes lamps and other parts in the area to
26. color dents is not left is the g lower section There are other tools like straight edges A L Sa f s off External panel repair 5 4 4 Distinguishing elastic deformation and plastic deformation When a panel receives an impact the deformation that occurs is either elastic or plastic deformation Although normally when the force is unloaded after the impact parts where elastic deformation has occurred will return to their original shape However plastic deformation which stops this from happening often occurs as well A good panel repair method is to use force that restores elastic deformation In other words do not work on parts with elastic deformation and instead repair only parts where plastic deformation has occurred If you do that parts then elastic deformation will automatically return to their original shape Accordingly being able to distinguish between elastic deformation and plastic deformation is a requirement for carrying out panel repairs efficiently The edge of elastic deformation is not obvious in a visual check as panels deform on a relatively gentle incline Also if dents are pushed from the rear the deformation changes shape while moving the top of the panel In contrast when there is plastic deformation you re most likely to find sharp angles and peeled paint When you push a dent from the rear the deformed area will stay still while the surrounding panel surface will move W Deformation
27. deformation can also occur in the front grille front fender radiator panel and hood When impact is heavy the whole of the front fender will be pushed in the gap between it and the door will be come smaller and the hood will get stuck on the front panel The side member will bend near where it is attached to the suspension members and if there is a lot of deformation even the toeboard near the site where the mem ber is attached will deform If force travels as far as the front pillar the back end of the door will sag There will also be more damage to the wheel apron 5 Side collision and damage The type of deformation varies depending on the shape of the body and the area where the force was loaded When there is a huge impact not only the doors and pillars but also the floor and roof will deform Because force is loaded in the direction in which the entire side compresses the wheel base may be shortened and it may affect the front fender and rear quarter The floor is prone to deformation on the inner side of the site where the side sill is attached and where the center tunnel rises up 6 Back end collision and damage If the impact force is minor damage will be limited to the rear bumper and around the rear skirt However if im pact is greater deformation will occur in the rear floor pan rear side members and roof In the case of the quarter panel if impact is minor the fender area will bulge and if impact is major the area up
28. edition of the service manual Height Within 1 5 Right side Right 10 cm Left 20 cm Left side Left right 20 cm 3 Completion checks for repair sites Make a visual check of the repair sites and adjacent panels to check weld finish and to see if bolts have been tightened Check for water leaks by hosing damaged vehicles that have had window glass and door weather stripping re placed and repairs to panels associated with the passenger compartment and the trunk Road test all the cars when repairs have been completed and check the operation of the engine meters trans mission brakes steering etc Also check for any strange noises or vibration Drive carefully so as to avoid an accident Quality inspection 13 4 4 Panel arrangement Refer to the body repair manual for the reference values for the panel arrangement They are set taking adjacent panels into account and there are cases where the gaps specified in the reference values cannot be rigidly maintained Although there is some variation depending on the site the permissible limit is 0 5 1 0 mm Reference value Between front hood and front grille 6 0 1 0 mm Between front hood and headlamp 6 0 1 0 mm Between front hood and front fender 3 5 1 0 mm Between front hood and front fender end only 4 8 0 7 1 0 mm Between front fender and front pillar 3 0 1 0 mm Between front fender and side sill 3 0 1 0 mm SS Quality inspection 13 5
29. finger as a fulcrum use the weight of the head to make it fall naturally Don t use only the power from your arm Use power from the arm only to direct the hammer When beating repeatedly and fast make fast snapping motions using your wrist as a fulcrum If the face of the hammer or the panel surface are at an angle you will make unnecessary marks on the panel The basic rule is to hit the panel with the face parallel to the panel It is not so easy to make marks if the outer perimeter of the panel is rounded Try to regulate the number of hits per unit of time and intervals as much as possible If they become irregular unstable force will cause a not so good result To prevent the panel from stretching don t continue beating the same spot numerous times Gently hold the end of the hammer handle and make snap motions using your wrist gt Hit the panel with the face parallel to the panel External panel repair 5 14 2 Hammer care Use wears down the face and causes marks so make regular checks and remove dirt etc Grind the face to tidy it up if there iS wear or marks Carefully grind the face using a flat file Put it in a vice and file it from different directions When finished plane the edges 1 2 mm and finish by sanding with P400 800 sandpaper Occasionally check the part where the handle and head are joined and adjust so it doesn t rattle If it is loose hammering will become unsteady It is even more dangero
30. hammer and dolly beat the sheetmetal so as to shift it from the pe rimeter of the heated area towards the center The secret is not to beat too hard Then immediately cool the heated area with a water soaked sponge or cloth Hammer quickly because if the metal cools while ham EAS mering it won t have any effect E ie ge Using this method once will shrink an area with a diameter of approxi mately 10 cm If the stretched area is large this has to be done a number of times In such cases first shrink the center of the stretched area and then the surrounding area Wet cloth Lee kK External panel repair 5 24 Sheet metal treatment 6 1 Chapter 6 Sheet metal treatment Contents Ms FRUSU NO e d Le EE 2 CT AU SS d E 2 SE SE ge aioir tasecanqpeateaesseanimeaninesentaeneagiutanainecebnaensaced 3 2 Surface preparation EE 5 Poan EE 5 2 Substrate treatment procedure sicscssccncdsderstacvawnsesaces cndnasaiesadenscadennineeddende dusa onidaanmsanuinadneidicnedslidenusidebsancoubadas 6 Sheet metal treatment 6 2 1 Rustproofing 1 Causes of rust As seen in the iron ore refining process iron used to make sheetmetal exists in the natural world as ferric oxides FeO and Fe 0 In other words iron itself is an unstable element and exists joined to oxygen This is why oxygen is removed when making iron materials Conversely it means that iron combines easily with oxygen Oxidation is rusting and oxygen which c
31. looks Because all of it is compressed apply force so as to stretch it to its original length External panel repair 5 20 2 Repair work Pulling from both ends to stretch the creases and repair the deformation easier if the panel is taken off If force is applied to stretch both ends of while maintaining the pulling force the panel it will regain some of its original shape If force is removed wes A Ze at this point because it will shrink for a second time while deformed stabilize the shape by beating the sharp angled part Zb E re ES Panels with this damage are perfect for practicing beating skills PSS If this type of deformation occurs in a bolted on panel repair will be 9 Sheetmetal shrinkage 1 Causes of stretching When comparatively soft metal like gold is beaten a number of times it will become thinner and its area will in crease This is called metal ductility Sheetmetal has the same property As a result when an impact or force is applied for making a repair it will get thinner and the area will increase This is sheetmetal stretching Because when part of a panel tries to stretch the surrounding metal stays the same it can t increase its area As a result that part of the sheetmetal becomes sur plus It changes from its original shape by rising a little and rumbles when pushed To repair the stretching this part of the sheetmetal has to be shrunk Shrinking is done by using the stretching and shri
32. mainly coated on joints to prevent water from getting in Check the body repair manual to identify the sites where sealer has been used and if repairing a panel where a sealer has been used make sure you seal the same site using a designated sealer or a repair product with the same performance Make sure you seal underframe parts Hood door and tailgate panels are already sealed W Examples of sites where sealers are used LSC 4 ele W j Pa SE ch Wu ee leie alll ACA Tite hh Sheet metal treatment 6 4 2 Anti chip coatings Sides sills and other sections are coated with an anti chip coating to prevent rusting caused by peeling paint film caused by flying stone chips Sealers are thick and form a moderately uneven painting surface Since there are different kinds check the model in the body repair manual and apply the same paint treatment using a similar repair product 3 Rustproofing wax Rustproofing wax is applied to the inside of pouch type underframe parts hinges hood door rear gate and some side sills Check the body repair manual to identify which sites have been coated in the body repair manual and if repairing a panel that has been given a coating of rustproofing wax rustproof using the designated rustproofing wax or a repair product with the same performance 4 Undercoat Undercoat is applied to underneath the body suspension etc Check the body repair manual to identify which sites hav
33. must be in line No gap between panels No rust stain or paint film on the joined surfaces Handling of welding equipment 4 Tip shape If the tip of the electrode tips do not make contact parallel to the W Shape of tip workpiece they cannot function properly The prescribed shape should be maintained as this has an affect on quality The diameter of the ends of the tips depends on the thickness of the It should not be angled due to wears or there should be no dirt or scratches workpiece If the panel is thick the area of the tip will be larger as it has to generate more current The following formula is used Electrode tip diameter 2t 3mm diameter tis panel thickness If sheets are of unequal thickness calculate using the thickness of the thinner sheet For example if there are sheets measuring 0 8 mm and 0 9 mm the formula is panel thickness 0 8 mm x 2 3 4 6 mm Use a tip cutter or file when the tip diameter is too big the upper and lower tips do not engage properly and there is dirt on the surface If a tip is worn or bent replace with a new tip Pressure welding force Since quality will be affected if a certain amount of pressure is not exerted during spot welding before welding check the pressure using a test piece with the same thickness as the welding site Old panels due to be discarded are useful for this purpose 4 Welding criteria Criteria to be considered when sp
34. out any excess adhesive with an applicator When installation is completed leave the vehicle for about 24 hours Follow the adhesive manufacturer s guidelines for the mini mum drying time and the length of time the vehicle should be left before it is driven Once the adhesive has dried pour water over the outside surface to check whether there are any leaks When returning the vehicle to the owner tell the owner not to subject the vehicle to any hard knocks for at least three days W Cut back the adhesive 1 k 3 2 4 1 Adhesive 2 2 mm 0 08 in 3 Rubber dam 4 Glass M Applying the primer 1 s _ N 1 Application surface of the primer 2 Glass side 3 Body side mM Applying adhesive 2 1 9 12 mm 0 35 0 47 in 2 8 mm 0 31 in M Clip the locating pin and attach the glass Removal and fitting of parts 8 9 4 Electrical components wire harness Vehicles are fitted with many electrically operated parts They are covered with elab E Connector orate systems of wiring wire harness used to supply electricity and to control the i parts When attaching removing electrical parts make sure you take off the negative ter minal on the battery beforehand If removing parts with a memory function like the audio unit and control unit record the memory contents before taking off the nega tive terminal If you neglect to do this all contents in the memory will be eras
35. patterns and repair points Wide mild deformation Deformation in the form of creases Long narrow deformation In most cases top and bottom Deformation at the center of the panel are plastic deformation while left and right are elastic deformation Plastic deformation po ae Elastic ee ts deformation Looks like being bent e E Paint is peeled It is easier to restore by repairing only this part Deformation near the edge of the panel Plastic deformation Stretch by pulling from front Hammer while and back before repairing force is applied Elastic deformation _ Large stretch of the sheetmetal generated surrounding area at the corner and other sections Paint film around will be lifted Den the dent and inside L 7 the dent are partially peeled External panel repair 5 5 5 Panel beating methods for different repair sites Hydraulic equipment is used when strong force is required for pulling though most repairs to outer panels are done manually Hammering or tapping is when a panel is placed against a dolly or body spoon and the deformation is repaired by beating with a hammer This requires you to be able to reach your hand round to the back or to insert a tool instead In contrast pulling is when a slide hammer dent puller or stud pin washer welder sometimes this is simply called a stud is used to repair the panel by pulling it out There are different types of pulling There is vacuum pul
36. set values Areas at the front that affect wheel alignment the most are the area around the strut mounts and the area near where the front arm is attached The wheel apron and the side frame are the panels that have the largest effect At the rear deformation of panels around where the suspension is attached affects alignment Empty vehicle Empty the trunk but fix the spare tire jack and repair tools and fill up the fuel tank W Main factors in wheel alignment Front wheel steering angle turning radius Camber Caster Kingpin angle F Toe in In some cases it is indicated with this angle The added angle between the camber and kingpin is called included angle W Ensure consistency for all four wheels Axle inclination nl Wel o d Not only the individual elements but the relationship of each position and balance are also important Quality inspection 13 3 2 Adjustments to electrical fittings and headlights It is important to check the operation of the various electrical parts once repairs have been completed Head lamps often have to be replaced in association with repairs and also look out for incorrect connection and poor contact Safety regulations determine the direction and range of illumination for headlamps When headlamps are re moved and replaced as a result of repairing a radiator panel test and adjust the headlamps using a headlamp tester while referring to the chapter on lighting systems in the Body
37. specified safe storage place If gasoline leaks onto the floor of the workshop do not leave it but wipe it up straightaway 2 Paints With the exception of water based paints most paints are flammable Store them in a specified place and do not leave them lying around elsewhere As an environmental protection measure always secure lids and caps to prevent the evaporation of volatile organic compounds Also be careful when disposing of leftover body filler cloths containing organic solvent based degreasing agents and used paint cans as there is the risk of spontaneous combustion Volatile Organic Compounds 3 Gas cylinder Be careful when handling acetylene gas oxygen gas carbon dioxide gas argon gas etc used when welding and also watch out for hose deterioration and the aging of equipment 4 Naked flames and other fire sources strictly prohibited Welding sparks can cause flammable gases to explode when gases reach a specified concentration within an enclosed space Therefore do not bring any fire sources into the workshop except those required for work Smoking is prohibited while working Use a specified smoking area W Many pieces of equipment used for work are highly dangerous CO Wy WZ Paint Carbon dioxide gas Gasoline Acetylene gas Health and safety measures 1 7 3 Health and safety related to body repair 1 Body repair work Body repair and welding work are highly dangerous tasks B
38. the adhesive 4 Do not cross the wire and do not pull hard against the edge of the 3 glass Be careful not to damage nearby parts Os Us t 1 Cutter 2 Protection tape 3 Locating pin 4 Knife for windshield glass mM Removing using the piano wire Removal and fitting of parts 8 8 Fitting Remove dirt from the surrounding area and using a cutter knife cut back the adhesive on the body to create a smooth surface around 2 mm 0 08 inch thick Be careful not to mark the body or painting surface Next align the positions of the locating pins on the glass side and the holes on the body side and place the glass against the body Adjust the position and after clearance at each of the four corners has been evened remove the glass and fit the rubber dam Align the molding mark with both upper edges of the glass and fit the molding from the upper corners to the center Attach molding double sided tape evenly to the side of the glass Using a sponge coat primer on the adhesive surface on the glass side and body side At this point because primer that gets onto the body painting surface or the interior trim is hard to remove cover the surrounding area Let the primer dry for around 10 minutes Do not touch the primed surface Apply adhesive to the edges of the glass then using a rubber suction cup insert the rocket pins on the body side and attach the glass Push lightly and make sure it is fixed in place Even
39. ton to Steel EE 4 1 Sheet metal manufacturing procesS cccseseccecsssseecceessceeceeueeeecsuasececseaseeeseeaeeeeeaeageeseseageeeessageeesseaseeseeas 5 4 Type of sheet metal EE 6 1 Hot rolled sheet metal and cold rolled sheet metal 6 2 Corrosion resistant sheets wecdesicxsinctedewexindebsisetiwainnentctwaseianvncedd deanxtnceeatjsnaidecttidwaxencdelectsleseeacktsleseeenenteeaeiamestiect 7 3 High tensile strength sheet metal BEEN 8 4 te in Ga ite tele Ken UE 8 5 Properties OF sheet SECON E 9 P Plasticity and elasticity E 9 ZINOK Aard Elte soraa ERE T E E E 9 3 Work hardening ege TE 10 CE E S Ea EE 11 6 Aluminum alloys EE 12 D Typesand ch haraoteristigS EE 12 I EE LE 13 Oe WS ANG EE een 13 2 Plastic body EE EE 14 Ee 16 WS ANCL EE 16 BE Ee EE 17 to TOW to distinguish types of Glas E 17 Body materials 3 2 1 Types of materials Sheet metal is the main material used in body panels A variety of elements are added to iron and flat stretched sheets used as exterior panels are 0 6 0 8 mm thick and those used for pillars and frames members are 0 8 1 4 mm thick Corrosive resistant sheets are used for sites where rust prevention is important and high tensile strength sheets are used for sites requiring high strength Corrosive resistant sheetmetal is normally zinc plated on both sides Repairing corrosive resistant sheets sometimes requires special treatment before applying putty or primer surfacer before
40. whose ends are both blocked by walls It becomes red and soften When the center of the rod is heated the heated area will soften and the entire area will bulge and try to lengthen Because both ends can t lengthen as they are blocked by the walls the swollen part will shift to the area in the center that has softened If the metal is cooled rapidly while in state the iron rod will try to return to its original length However the total length will shorten because the area in the middle will have cooled and locked up External panel repair 5 23 4 Order of tasks 1 Heat shrinking using a welder It is usual to carry out heat shrinking using the shrinking function of a spot welder or stud welder If the stretched area is not large turn on the welder while pushing the shrinking electrode rather hard against the center When you take it away cool it straightaway with an air duster gun If the stretched area is large begin at the perimeter of the stretched area and move toward the center in a spiral motion W Heat shrinking using a welder 2 Shrinking using an oxy acetylene welder Gas welding was the main method used for shrinking before heat torch With the gas flame heat the center of the stretched area so that a spot AN around with a diameter of around 10 mm heats to a red color Next us t shrinking became common However this requires a lot of practice D Gas welding Q ing a
41. 5 The principle behind a measurement plane A plane is made at a set distance parallel to the body It is possible to show the correct positions on the body us ing positions on this plane and this distance between the plane and the various areas on the body As a plane it doesn t have to be a plate like surface with no gaps A virtual plane is also acceptable This is the basic principle behind jig type measuring systems Apart from ordinary jigs there are also systems that extend arms from the frame to create a virtual plane and have attachments provided with measuring tapes Body dimension charts show the dimensions of a projected plane W Measurements using a virtual plane Virtual plane for measurement Jigs platform floor surface measuring device etc 3 How to read body charts 1 Body dimension charts Body dimension charts show the true dimensions of new vehicles and are used for vehicle alignment They are included in body manuals for each model Because with a unitized body the engine and suspension are directly attached to the body their layout has a bearing on traveling performance and safety For example if the position of strut mounts is incorrect the wheel alignment will be out the vehicle won t travel straight and the tires will suffer from abnormal abrasion If you have a body dimension chart you can proceed with body repairs even if the new panels haven t arrived 2 Linear distance measurements and pla
42. Like an egg shell the outer skin made of a uniform material spreads force applied to one part across the entire body thus maintaining strength Because a vehicle body has opening parts like doors and the engine bay pillars and members are used to ensure strength Since the amount of force received differs from site to site strictly speaking this can t be called a unit ized structure In Japan this is referred to as a monocoque body whereas overseas it is called a unitized body or frameless body In a unitized body the underframe is made of closed section members and the heavy engine suspension steer ing etc are attached directly to the underframe One notable feature of this type of construction is that it allows the use of panels that are thinner than a frame This is a good structure from the point of view of its light weight impact safety and mass producibility W Egg shell has a stressed skin structure W vehicle is not really like an egg as it has many opening parts The force is absorbed by the entire exterior of the shell Body construction H 4 3 Rigid and truss structures The frames of ordinary buildings have a rigid structure and a truss structure Beams and perpendicular members form a quadrangle which form a house or building when supported by pillars In a rigid structure the contact points have rigid joints A rigid joint is a joint that has been welded so that it can t move A truss structure has
43. SUBARU Body Repair Technical Skills Handbook gt SUBARU Introduction This manual sets out know how required to carry out auto body repair for those wanting to acquire auto body repair skills through to those already engaged in repair work in the course of their jobs It goes without saying that knowledge a sense for the work and practical know how acquired through practical experience are important when acquiring expertise in body repair However at a time when advances to the quality of materials construction and assembly precision used in vehicles are improving at an almost daily rate gaining a firm understanding of basic knowledge is essential for carrying out effective and reliable repairs of a quality that will meet with customer satisfaction This handbook will first describe basic knowledge of health and safety vehicle body construction and then cover the basic procedure step by step from external panel repairs and underframe repairs to the replacement of welded panels providing general examples Table of Contents Health and safety measures Body construction ee SUBARU Body materials Subaru Body Repair Technical Skills Handbook Sheet metal treatment N LA 6 bal Damage analysis Removal and fitting of parts LD Repair of the underframe Handling of welding equipment 10 Replacement of welded panels 11 Repairing aluminum alloy and plastic panels 12 ech LA Qual
44. The radiator and air conditioning unit fitted at the front of the en gine bay are often involved when repairing a vehicle These parts have to be removed when they are damaged and also when the radiator panel is replaced Always top up the radiator but if the level of water drops due to radiator damage it must be filled with water and the prescribed ratio of coolant Recover and fill air conditioner gas using special equipment Dis pose of the gas following recycling regulations Other work will require the removal and filling of other solutions such as power steering fluid brake fluid engine oil and trans mission oil Since these are all vital for vehicle safety you must follow the guidelines set out in the service manual Removal and fitting of parts 8 11 E Filling the refrigerant Removal and fitting of partsl gl 12 Repair of the underframe 9 1 Chapter 9 Repair of the underframe Contents 1 Order for inner panel and underframe repairs ccccceeeceseecseeeeeeeeaeecueeeeeeseaeeeasecaeeeeauseaeecaeeseeeseaeeseesaees 2 2 Body adjustment and alignment equipment ccccceeeceeeeeeeeeeeeeeeeeeeeesaeeeaeseeesaeeaaseensanesaneseeseaesaneseness 3 SR ee Eu Ee EE 3 AME elcome ate lela yclec e ee 3 BS 96nd d VTT E 6 SR LC OS OT SOL E 6 IBS nt e a e e EEN 7 REI e e D EE 8 4 Setting up repair equipment EE 9 1 Setting up floor type equipment EE 9 2 Setting up platform type equipment E 10 3
45. a guide to points requiring attention for various sites First tires and wheels are often removed and fitted when repairing a vehicle Ride comfort and safety are impaired as a result of vibration caused by imbalance in tires and wheels due to some spots being heavy or light A wheel has both static balance and dynamic balance Special equipment wheel balancer is used to measure position and weight A small weight is attached to the edge of the wheel to regulate balance but if it comes off as a result of impact caused by a collision the wheel s balance will naturally be affected Check carefully when removing or fitting tires or wheels and if it has come off the tire and wheel as sembly will need to be balanced Because the wheel alignment is not the same for each wheel once you have removed a wheel make sure you return it to the same place To do this when removing wheels mark them to show their location for example right front or left rear Checking tire pressure is one item to be checked before returning a vehicle to the owner When attaching or removing wheels and tires check the torque and make sure they are not secured too tightly 2 Windshield glass E Direct bonding method Body flange 1 Attachment Mole The attachment of windshields and rear windows not only seals a cabinet but it is also used to retain vehicle strength The windshield is attached using either adhesive or weather stripping Adhesive method Glass at
46. ade from plastic are used for a variety of parts including the bumper face It s necessary to know the properties of the plastic used for each site and to take them into account when making repairs A special kit can be used when filling welds patches and dents with putty Do not use a hammer It s more common for this to be done by those responsible for painting There are natural and synthetic plastics Petrochemical synthetic plastics are used for automobiles There are thermoplastic and heat curable synthetic plastics These have different properties 1 Types and characteristics 1 Thermoplastic plastics Thermoplastic plastics become soft when heated They return to their original state when the temperature is lowered Polypropylene PP Has a light specific gravity and excellent strength rigidity thermal resistance electrical properties water repellency and chemical resistance Uses Bumpers headlamp housing Polyethylene PE Has excellent transparency chemical resistance and electrical properties Has poor strength rigidity and thermal resistance Uses Mudguard air flap Polycarbonate PC Has excellent impact resistance thermal resistance and weather resistance Has poor fatigue strength Uses Headlamp lenses Acrylic PMMA It has high transparency which is why it is used for paints Also has good strength and workability Is sensitive to impact or organic solvents Uses Lamp lenses ABS A
47. ainst the panel and beating a standard hammer against it Dolly A dolly is a block of metal that fits in the hand A dolly is used to hold the surface being hammered or a nearby site A dolly can be used instead of ahammer for places where a hammer can t reach Choose a dolly with a shape most suitable for the repair site Spoon lever A steel rod where either one or both ends have been shaped like a thin spoon A spoon can be used instead of a dolly to reach places hard to reach with your hand It can be used like a lever when mak ing panel repairs They come in a variety of shapes and lengths for different sites A lever has an S shape and has sharper angles than a spoon and has bent tips Chisel Although a chisel is usually used for cutting panels and removing welds chisels are used for beating press lines because of its wide semi cylindrical blade When chisels such as cold chisels are used the end is hit with a ham mer In such cases a bumping hammer must not be used Center punch A center punch is normally used to make a dent in the center so that the drill blade does not slip when making a hole In panel beating it can also be used to hold down a high point Unlike a pick hammer the repair site can be lowered without the center punch slipping off the repair site St ee C2 L Spoon j Lever External panel repair 5 9 2 Stud welder Called a stud pin washer w
48. ape for the par ticular site There is a variety of other tools including special light sources for looking at dents and magnets at tached on the front side to make it easy to find the exact spot E Hammering a M Dent repair tools M Pulling External panel repair 5 7 4 Pulling points lines and planes Simple damage caused by a single entry point can be repaired by pulling with the appropriate amount of force In reality however such simple damage rarely exists In principle it is easier to pull a line than a point and pulling a plane is even easier When pulling a point depending on how much strength you use you can pull too hard on just the point at the center If hammering of the surrounding area is neglected the deformation can become more complicated There is therefore a tool that is used like a lever so that by pushing down on the surrounding area the center is pulled with a pinpoint For damage that runs along a line there are also tools that will pull an entire long line For planes there are pulling methods where a plate is attached using a special solder 5 Body repair tools equipment and materials 1 Hammers 1 Role of the hammer The hammer is a tool that has come to symbolize body repair However in body shops today apart from the res toration of classic cars you won t find repairers using hammers and dollies to beat panels of every conceivable shape to restore them to their original
49. are those that have high resistance when pulled compressed and bent The surface of a hard metal is not damaged when load is localized Steel is the strongest metal lead is the weakest 2 Ductility and malleability Ductility is a metal s ability to be drawn or stretched and malleability is a metal s ability to be shaped or bent Together ductility and malleability are called forgeability This is also called plasticity Steel aluminum copper and nickel have this property 3 Brittleness and toughness A brittle material bends and breaks easily A tough material is strong Cast iron is brittle and steel is tough 3 From iron to steel Sheetmetal is made by rolling steel into thin sheets Steel is made by melting iron ore the raw material and removing or adding elements after the iron is separated Iron itself is hard to use as it is brittle when hard Steels with a variety of characteristics can be made by adjusting elements besides iron Carbon is an important element and the more carbon is added the harder the material There are different categories of carbon steel depending on the amount of carbon added such as soft steel and hard steel Other elements added to steel besides carbon C are silicon Si manganese Mn potassium P and sulfur S Although they are added in small quantities they make a difference to the properties of steel They generally increase strength but steel can become brittle if large quantities are ad
50. at gun about 1 2 cm from the weld site and fill in when the bottom of the welding rod and the damaged area melt together Check that it has returned to room temperature and remove any excess from the surface using a knife or a cutting disc If using a power tool use at speeds of below 1 500 rpm If the speed is too high the heat may cause melting Sand the surface with P240 paper Mask degrease and clean If the plastic is polypropylene paint with a PP primer before starting the painting process W Cut a guide slit dei 1 ZL 4 2 1 Painting surface 2 PP base 3 20 30 mm 4 3 mm W Fill in the groove using a heat gun 2 2 3 1 Welding rod 2 Area to be welded 3 Cross sectional view e Melt the site shown by the shaded area e To retain strength do not melt until the welding rod starts to flow WW Remove excess from the surface and sand with paper Fe y g Repairing aluminum alloy and plastic panels 12 6 Quality inspection 13 1 Chapter 13 Quality inspection Contents 1 Wheel alignment EE 2 BOO Y GMC AVACE Ei ele ut GE 2 2 Fac O ee CS MEN 2 2 Adjustments to electrical fittings and headlights ccccccceceeeeeeeeeeeeeeeeeeeeeeseeeseaeeesaeeesaeneesaeessanessaeeesas 3 3 Completion checks E 3 4 Panel arrangement assnssnnnnnunnnnnnnnnnnnnnnnnnnnennnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnennnnnnnnnnnnnnnnnnnnnn nunen n nnnnnn nennen nenanem nenne
51. ate for welding As evaporation heat causes carbon dioxide gas to freeze when it leaves the cylinder so a heater is attached to avoid this Check for gas leaks from the regulator daily using a soap and water solution Handling of welding equipment 8 7 Welding 1 Seam welds Seam welding is when two overlap ping panels are welded Secure the two panels leaving a gap of 1 2 mm between them and weld continuously while filling up the gap Because heat will cause distortion in the surrounding area if you attempt to weld a long distance at once make a weld stop for a moment and then con tinue with suitably spaced intervals 2 Plug welds spot welds Plug welds are made to supplement E welding done using a spot welder Plug welds are made at sites where there are a number of panels to be joined sites that require strength and sites where spot welding is difficult First make a hole in the top panel at the weld site The diameter of the hole varies depending on the thick ness of the panel A diameter of 5 6 mm is suitable for a 0 8 mm thick steel sheet 3 Fillet weld eege A fillet weld is used to weld the ends of one panel laid on top of the other 8 Conditions of use 1 Weld area Do not leave a gap between panels and perform the neces sary rustproofing treatment Remove any rust or moisture 2 Distance If the distance between the end of the tip in the nozzle and t
52. auses rusting is in the air makes up around 21 of air Most is nitrogen 78 Oxygen is also in H 0 or water the cause of moisture that is in the air Rust is accelerated when salt NaCl is added and rust forms easily in coastal areas exposed to the sea and in regions where anti freezes are used If iron is left it will combine with oxygen and rust In the case of iron rust will migrate from the surface to the inside This causes holes reduces strength and makes iron brittle Painting is a means of preventing rust and rustproofing is improved by applying a coat of sealer or an anti corrosion agent Salt Coastal regions and regions where anti freeze is used Sulfur discharged from factories becomes sulfurous acid gas and iron rusts even more Pollutants when exposed to this gas Acid rain also plays a part When there is a huge change in air temperature if iron comes into contact with a different Difference in electrical metal an electric current flows and the positive side rusts potential lron Aluminum gt Aluminum lron Zinc gt Zinc Mi Causes of rust When moisture is attached to a sheetmetal iron will seep Water H20 into the water as ion combines with OH ion in water and becomes ferrous hydroxide Fe OH If oxygen is further 2 Air D a Oxygen y i 02 OO 20 bonded it becomes ferric hydroxide red ruster Fe OH Sheet metal treatment 6 3 2 Rust prevention 1 Sealers Sealers are
53. beam like member where there is an angle bend An example is the end of the front fender which has been bent at a right angle 2 Channel As the name suggests this has a U shape and is seen in processing of side frames 3 Box For underframe areas like side sills and pillars that require high strength two Lo U channels are joined together to form a box 4 Beading Beading is the formation of a step in the middle of a panel to create a dent or bump to reinforce a flat panel such as the floor pan 5 Hemming The edge of an area where an outer and an inner panel are joined is pressed so that the outer side is tucked over the inner side This method is used for the edges of doors and the hood 6 Crown Low crowns are often used in the roof hood and fender because of their design but SES due to their low strength they are combined with a high crown or a reverse crown a in order to maintain strength The different types of crown are the reverse crown the low crown low curvature and the high crown high curvature Body materials 3 11 4 Tensile strength Strength and rigidity have different meanings Strength is resistance to outside forces such as pulling compression and bending in other words break proof and is largely used in connection with materials Since it is the amount of force that can be withstood it can be evaluated using figures from objective measurements In contrast rigidity is an abstra
54. ce scratches are also left by panel beating In such cases a primer coat is applied to the substrate to prepare the surface for spray painting with a top coat the same as the body color 3 The line between panel beating and painting The line between panel beating and painting differs from workshop to workshop In cases where ma chines and tools are used to repair panels only a panel beater does the work up to the point just before the painting of the top coat In some cases the line is drawn before the painting of the primer coat In general it is common for a panel beater to be in charge of work up through the sanding of body filler to create a smooth surface In some cases the work is divided into the three tasks of panel beating painting and the substrate and in some cases no distinction is made between panel beating and painting In such cases the aim is to ac quire skills so that the same person is able to work on every stage Work procedure Damage analysis Preparation Removal of parts Underframe repairs Replacing welded parts Panel beating exterior panels Repair and paint Fitting parts Completion checks Analysis of the accident conditions Diagnosis of the damaged sections Measuring body Examining determining repair procedure Selecting body repair equipment Examining removal fitting area of the related parts Man hour for removal and fitting Fastening with the
55. chored to the bench the vehicle to the adjustment and alignment equipment and the equipment to the bench Raise the bench with a hoist Support the car with wheel stands Set the underbody clamps and raise and lift the damaged car or a rigid rack that can be used the bench again and remove the stands from the gaps of the bench and lower the bench Repair of the underframe 9 11 4 Anchoring the damaged vehicle horizontally Different systems have various tricks to loading vehicles that make the work more efficient It is important that you grasp these various features For almost all models it is important that the damaged vehicle is positioned horizontally To be accurate the axis of the bench or platform should be parallel with the vehicle With floor systems the vehicle should be positioned parallel to the baseline of the measuring system or if the floor is level the vehicle should be anchored parallel to the floor 5 Measuring the body 1 The purpose of measuring The body is measured to determine how misaligned the various parts of the deformed body are 1 Length The simplest measurement is to compare the length For example if the left fender is shorter than the right front fender the left side has been pushed in However this is not an accurate assessment This is because it is possible that the right side has stretched 2 Diagonal measurements Another way to compare measurements is to compare the diagonal measu
56. contour as was the case some years ago Ihe reasons include advanced technology is required it takes time and the price of parts is relatively inexpensive and they re also easy to obtain 2 Hammers and related tools The term hammering is used for various tasks performed using a hammer There are a number of other tools required for hammering and there are also different types of hammers The main types of hammers are listed below Bumping hammer The bumping hammer is indispensable for repairing panels At one end the face is a round flat striking surface while face at the other end is thinner and slightly curved The precision of the striking surface is different from hammers used to hit nails Do not use these because they could leave a dent Although of a similar shape those that are bigger are used for rough ing out Shrinking hammer The striking surface is cross milled like a file and when shrinking stretched sheetmetal the hammer is used in combination with a dolly with a similar type of surface Pick hammer A hammer with a thin sharp point Used for repairing very small pro trusions and dents External panel repair 5 8 Mallet A mallet is used to apply light force when you don t want to remove paint or stretch the panel The head is made of wood Hammers with a plastic head can be used for the same work In some cases you can get the same result by placing a small piece of wood ag
57. crylonitrile butadiene styrene Has good formability but has poor thermal resistance and weather resistance Uses Front grill 2 Heat curable plastics When moulded and hardened at high temperatures heat curable plastics will not soften if heat is applied Polyurethane PUR Has excellent elasticity wear resistance and oil resistance but is not very resistant to acids or alkalines Uses Also used in paints and adhesive materials Ils used in foam form as a heat insulating and sound proofing material Unsaturated polyester UP Has excellent strength rigidity and electrical properties Has poor contractility and thermal resistance Uses It is used in fiber reinforced plastics Body materials 3 14 Epoxy Has good strength and electrical properties but has no elasticity and yellows easily It is also expensive Uses It is a high grade plastic used in fiber reinforced plastics Fiber reinforced plastic FRP FRP is made by impregnating unsaturated polyester with glass fibers to attain a high strength The strength is increased if carbon fibers are used CFRP Uses Body panels 2 Plastic body parts and materials 6 7 Body materials 3 15 W Examples of plastic parts and materials 1 Headiamp ens SE PP Extension 15 Rearbumper aer 2 Front fog lamps standard Bracket housing 3 Front bumper ace 17 Backup lamp og lamp cover a 18 Rear combination lamp Side bracket Corn
58. ct term that refers to how something holds together It is mainly used in connection with fabricated items A material maintains the same strength no matter what kind of part it is but its rigidity changes depending on the shape that is made and how it is combined One indicator of the strength of sheetmetal is tensile strength which is mentioned in the previous chapter on types of sheetmetal Tensile strength is measured by putting a thin long sample in a tester and pulling on both ends and seeing at what force the sample breaks The relationship between load force and the amount of deformation pull changes as shown in the graph Although when sheetmetal is pulled it stretches slightly in proportion to the force from a certain point this will decrease and it will reach its elastic limit When force is re loaded it will stretch to its upper yield point stress will decrease it will continue stretching irregularly until it reaches its lower yield point when stress and pull will increase and it reaches its maximum stress point This point is tts maximum tensile strength From this point only stretching will increase and it will break The figure showing tensile strength is calculated by dividing the maximum load N B in the graph by the cross sectional area mm of the sample While elasticity plasticity and work hardening are common sheetmetal properties in this graph plastic deformation is reached when force exceeding the elastic limit is loa
59. d and that the temperature isn t too high Though aluminum is easy to repair because it doesn t crack when heated there is a limit to how hot it can be heated which if exceeded with lower strength Despite some variation depending on the particular aluminum alloy the threshold is 200 250 C Check the temperature with a contactless thermometer 4 Welding Since aluminum alloys require a large current due to their electroconductivity welding cannot be done using a spot welder used for repairs There is a dedicated MIG welder that uses aluminum wire If using this use argon gas as the shield gas as you cannot use carbon dioxide gas Repairing aluminum alloy and plastic panels 12 3 5 Surface preparation Follow the same procedure as for sheetmetal feathering priming and filling Because some substrate paints can be used on aluminum alloy as well as sheetmetal and others are made for aluminum alloy only check the paint manufacturer s specifications Mi Pointers when repairing aluminum alloy Grinding Panel beating Heating Welding Substrate Use paper with a finer grit size than paper used for sanding sheetmetal Because it is softer Once the substrate appears immediately carry out surface preparation Only possible for elastic deformation Replace the part in case of plastic deformation Use a wooden hammer or plastic hammer Easy to stretch and to leave hammering marks Development of repair tools are in
60. d points Make a weld point in the center of the flange In vehicle repair it is often not possible to retain the spot points of a new vehicle Taking the performance of a spot welder used for repair into account around 1 3 times as many weld points as that on a new vehicle will ensure that strength is maintained In MIG plug welding the same number of weld points as a new vehicle is acceptable 5 Panel thickness limit Although it can vary depending on the performance of the spot welder being used generally spot welding should be done on panels no thicker than around 3 mm MIG plug welding should be used for greater thicknesses 6 Heating of tips The electrode tips will become heated if welding continuously Because when tips heat up the current is im peded there is friction and dishing occurs either take a break after a certain number of times or use a welder with a cooling attachment 6 Inspecting the finish There is a limit to the results of spot welding that can be as ENEE certained in a visual check Although a visual check will show Destruction of test piece SN Welded point spacing and dishing it won t show any cracks C Ser For this reason it is important to weld a test piece beforehand Rew SN A i O under the same conditions remove it and check its strength Ae Spotweld e X Weld test pieces with the x same thickness as the panel to be welded Then separate the test pieces Chisel a
61. d the old panel on the body After welding the key spots fill in the gaps and weld the whole part A seam of the thickness of an air saw blade is appropriate You can either put the new and old part together and cut once or cut using accurate measurements When cutting using measurements if the cut piece is too short there will be a gap between the panels To avoid this leave an extra margin when cutting and make adjustments at the end Similar to thickness of a saw blade Body side New part VW E kp oe MV Kat B E E Pe ae SA Put the new and old panels Positioning with a space Spot weld with appropriate together and cut once similar to thickness of interval to fill in the gaps a saw blade 2 Flanging Create a flange on one of the panels using a flanging tool and attach by either MIG welding a fillet weld or by using a structural adhesive This is restricted to sites where flanges can be made Ordinary flanging tools are used on flat surfaces However there are some tools used in panel bonding that can be used on crowns and corners 3 Adding reinforced panels Use leftover parts of new panels that have been cut for sites that require reinforcing Cut the same press line to H a length of around 50 mm and weld the part under the body side as a reinforcement panel Strength is further improved by laying the new panel on top and making a butt weld This method is suitable for the side sill and side frame
62. de whether to repair or replace The decision on whether to repair or replace varies depending on the type of panel to be repaired role extent of damage repair site technology and workshop policy Although a decision taking all factors into account is required opt for repair if the cost of repairs falls under 70 of the cost of replacement 3 Select repair equipment Once you have made basic decisions such as confirming the extent of the damage and deciding whether to repair or replace the damaged section you will need to select the equipment to use for the repairs Equipment ranges from simple through to embedded systems There are three fixed methods that use floor platform and jig sys tems and setting and resetting time also varies An effective way to repair small and medium size damage is to use a floor system that is easy to set 4 Gather and check model information on body structure etc Gather information about precautions concerning repair sites by getting materials such as body repair manuals 4 Removal of parts First wash the car to remove dirt and dust and then start repairs from the step required according to the extent of the damage Remove damaged parts that are bolted on parts that need to be removed in order to repair or remove damaged parts and interior parts that will affect the repair work It is common to remove welded parts at a later stage while making repairs to the underframe Repair procedures 4
63. ded W iron and steel W Types of steel a Carbon content a oe Soft steel 0 12 0 20 From 1 7 High carbon steel OVer 0 6 Body materials 3 5 1 Sheetmetal manufacturing process Steel is an alloy made by adding carbon to iron It is easier to mass produce compared with other metal materials is inexpensive and steels with a variety of properties can be made by adjusting the content of other elements and by heat treatment Steel that has been rolled into sheetmetal is highly formable and because it is inexpensive it is used in a wide variety of fields in addition to automobiles Sheetmetal is produced by the following process W Sheet steel manufacturing process Iron ore eee Coke Ingot Shaft a eme furnace Senn mea lron Steel making Ingot making Blooming manufacture Cold rolled Slab Heating furnace Hot rolled sheetmetal sheetmetal et Hot rolling Cold rolling 1 iron manufacture Iron is removed from iron ore Iron does not exist on its own but is found in compounds such as ferric hydroxide red rust Fe 0 and triiron tetroxide black rust Fe 0 magnetic iron ore Only iron is separated by removing the oxygen and others from iron ore which has a high iron content Steel is produced by removing other impurities as well 2 Steel making Raw iron has many impurities and because it is hard and brittle it is not used very much Steel with various properties is produced by removing impurit
64. ded Even when the force is removed the area that has deformed will not recover its original state Conversely when force below the elastic limit is removed the sheet will recover its original shape as soon as the force is removed The line shown in this graph applies to all sheetmetal In the case of high tension steel for example the elastic limit will be at a much higher force so this whole line will move further up to the right in the graph W Tensile strength and elastic limit B Maximum stress point maximum tensile strength A Elastic limit elastic limit point C Breaking point Upper yield point Lower yield point Load force Proportional limit Deformation pull EE Body materials 3 12 6 Aluminum alloys 1 Types and characteristics Aluminum is also used in auto body panels Because aluminum weighs about a third of iron per cubic volume specific gravity it weighs approximately half that of iron with the same strength It is also rust resistant and has good workability It is used as an alloy which contains other metal elements Because its properties such as thermal and electrical conductivity make it different to sheetmetal and it also has a different hardness it is handled differently when used to make repairs Aluminum s appeal lies in it being the lightest material It can be welded because of its thermal conductivity which is around twice that of iron It is used in auto body panels and mecha
65. der of entry and whether there is any pre existing damage Check to see whether it conforms with the information you have received and whether there are other sites that haven t been spotted Look for not only areas where damage has been caused by direct contact but also secondary damage and inertial damage caused by passengers or luggage Damage sites From the appearance of the damage sites deduce whether the damage is restricted to the outer panels or whether it involves inner panels and the underframe Stand a certain distance away from the vehicle and consider the site where the force of the impact hit the vehicle the directions in which it spread and the strength It s not possible to make effective repairs if you don t have a firm grasp of the location and extent of the damage W Checking the damage i In frontal collision even Impact Sturdy Impact if the cabinet is intact energy cabinet energy the rear side may be absorption absorption damaged section section Damage analysis 7 J 3 3 Checking measurements When checking the extent of damage make a visual check and use measurements Damage to the underbody can be identified by taking measurements using a jig or centering gauge For the up per body measurements alone can sometimes not be enough Because a visual check is not precise you should finally determine the dimensions of each site using a tram gauge or measuring tape mM Visual check M Checking by meas
66. der to all the directions of the putty surface Sanding tight curves Move the sander as if wrapping the peak of the curve Sanding gentle curves Move the sander to a constant direction at an angle Sanding press lines Press line When sanding consider it as completely different surfaces that are separated by the line Sheet metal treatment 6 12 5 Checking the finish For panels like outer panels of the doors and rear quarters where the vertical direction is curved but the front back direction is nearly flat check surface finishing using a straight edge Use a straight edge which is long enough to straddle the filled area put the ends on the unaffected surface and move the straight edge up and down If the gap between the straight edge and the filled surface is regular the surface is almost smoothed If a guide coat has been applied to the surface of the putty beforehand the remaining black spots will reveal the high spots and low spots Although it is common for panel beaters to do the repair up to around the sanding stage if a further surface fin ishing stage is required use this sort of guide coat and do the final finishing by hand with fine grit paper W Guide coat Damage analysis 7 1 Chapter 7 Damage analysis Contents ge CT Ve TEE 2 KEE OL CCI CIN eme 2 ZO orda ee e EN 2 CCCI Be Sl FS 0 US scree occa stern vara cae eanip ae RE E E aR 3 2 Underframe construction and damage
67. dopted in passenger vehicles where there is a single frame that supports the body engine and suspension and absorbs force while the vehicle is in motion There are other frames with a variety of structures besides the monocoque body They are broadly divided into the following 1 Ladder type frame Two parallel rails are joined by cross members and as the name suggests it is a simple structure in the shape of a lad der This frame is used for trucks and 4 wheel drive vehicles This is also called a ladder frame They are mainly used in passenger vehicles because they allow a large passenger compartment and have a low perim eter frame 2 Platform frame This frame s structure has robust floor panels that serve as the frame 3 Space frame This frame is made up of pieces of tubing With a shape like that of a motorbike frame the complex structure is not suit ed to mass produced vehicles 4 Backbone frame With a spine in the center like the space frame this backbone frame is suited to small production sports cars Body construction H 3 2 Characteristics of the unitized body An egg is an example of a shell type structure which can withstand a considerable amount of force when apply ing force using a finger on the top or bottom This is because the force is not concentrated but is absorbed by the entire exterior of the shell Called stressed skin construction it is used in the design of aircraft
68. dows a large area of the center body opens As a result there are pillars that extend vertically from the floor panel to support the roof panel The number of pillars is determined by the number of doors There is a raised floor tunnel running from front to back in the cen ter and a box section side sill on both sides that supports the weight of the passengers and cargo The sides are the same thickness as the doors It is not possible to construct an impact absorbing structure like that used at the front or rear As a result each pillar has a closed cross section structure with and outer and inner panel and a three layer structure is created by disposing reinforcements between the panels Reinforced panels are used to provide a robust structure for hard top bodies and convertibles that do not have a center pillar Mechanisms to raise and lower the windows and to lock the door are contained inside the doors and side door beams are adopted to enhance impact safety when a side impact occurs This reduces the amount of deformation when the door receives impact W Center body structure and parts SS p se ae Ser Ze e _ __ _ _ wc wech wech wesch oe o Ek WN gt S Roof panel Front roof rail Rear roof rail Roof center brace T stud plate Side rail inner Front pillar upper inner Front pillar center inner Side sill reinforcement inner Center pillar inner Rear quarter inner D pillar reinforcement assembly D pil
69. e added to glass used in automobiles There is laminated glass that has antenna wire integrated in the middle layer tinted glass where a tint has been added at the top of the middle layer tungsten heating wires embedded in middle layer to prevent fogging and mist and glass that stops ultraviolet rays Types of reinforced glass include heat absorbing glass that absorbs infrared rays which is made by added minute quantities of metal elements glass that absorbs and blocks ultraviolet rays heat reflecting glass heat ray printed glass printed with an electrically conductive paint and tinted glass to lower transparency and improve privacy 3 How to distinguish different kinds of glass At the bottom of automotive glass there is the JIS mark as well as the name of the glass manufacturer and symbol Mi Glass symbols denoting the type of glass Lea cr Z You can distinguish different types of glass from the Es symbols found below the JIS mark V 4 l3h OOO0 I5 L Laminated glass v T Reinforced A002343 LAMILEX glass amy Z gt Partially reinforced glass FEAN Le SS LP CENTRAL MIAJ P that denotes types is an additional symbol Body materials 3 18 Repair procedures 4 1 Chapter 4 Repair procedures Contents Ts Order Ol E 2 Ari HOG n EA A create peacver E AAT A A T EE gt yoy E E A A A 2 FANO EN 2 3 The line between panel beating and painting ccccsssccccssseececsesseeeceeuseeeceeaeeeee
70. e been coated and if repairing a panel that has been given an undercoat apply an undercoat to maintain the designated thickness using the designated undercoat or a repair product with the same performance Mask around the sites to prevent the undercoat from adhering to areas besides the designated sites Sheet metal treatment 6 5 2 Surface preparation 1 Sandpaper Sandpaper is used for surface preparation This can be done using a sander or attaching sandpaper to hand sand ing pads holders blocks There is adhesive or Velcro on the underside Since the shape size and positions of the suction holes for suctioning putty dust vary according to the type of sander used use sandpaper suitable for the conditions In addition to there being different kinds of paper for different materials and uses there are different grits The lower the number the coarser the paper Paper with a high number has a fine grit Grades with a P comply with the industry standard so different makes of paper will be the same The basic rule when using sandpaper is to start with a coarse grit size and move gradually to a finer grit making sure you do not a miss grit size in between This is because you will have to get rid of marks left by the paper W Sandpaper grades P16 24 60 80 120 180 240 320 600 1000 1500 Sanding metallic Rough sanding of Sanding polyputty Sanding primer Middle sanding surface the metal sheet putty surfacer of the top coat Rust remo
71. e teeth on the underbody clamps will face opposite to the pulling direction Underbody clamp Repair of the underframe 9 8 3 Supplementary anchoring Depending on the direction of the pulling force adding supplementary anchoring can make repair easier by making effective use of the pulling force Supplementary anchoring is mainly required in the following instances 1 To reinforce basic anchoring When chains are used for anchoring the direction of the pulling force can cause the chains to slack en In such instances add anchors in the opposite direction 2 To counter moment Not all pulling is done on the center of the body Adding anchors in the direction of the moment caused by pulling and the opposite direction of the moment will prevent further deformation 3 To prevent excessive pulling Pulling force travels to a fixed point and does not affect any points past the fixed point For example if you want to pull on the front half of the front frame anchors should be added immediately be hind the area you want to align Adding anchors to the opposite side when pulling from the side makes effective use of the force 4 To protect opening parts The upper part of the body is not anchored Con sequently when strong force is applied it can have an effect as far as the front pillars Therefore con necting the top of the front pillar and the upper sur face of the side sill will prevent deformation
72. ect way of pulling clamps Moment f Moment Pulling direction should be If pulling off center matched to the center of the the panel may be area where the clamps are scratched and being biting into the body disengaged easily Repair of the underframe 23 3 How to handle clamps and chains If clamps are handled badly they can t be used for long work efficiency falls and the risk of accident increases Be mindful of the following points in the daily use and maintenance of clamps Check the clamp s teeth A large amount of force is applied to the body via the teeth on a clamp If the teeth are in bad condition the force will not be transmitted Teeth have a trian gular profile so that when force is applied they will grip the panel and not slip If the teeth become round or dirt gets in the gap between the teeth their ability to grip will decrease and it will be easier for them to come off Clean and check the teeth regularly Don t over tighten the bolt Sometimes the bolts around the teeth that prevent the clamp from slipping or coming off are tightened more than necessary However because pulling force acts in the direction that the bolts are tightened they can t come off even if a large amount of force is applied A bolt will get damaged if it is tightened with more than the appropriate torque Check clamp bolts regularly remove dirt and dust from the grooves and coat them lightly with
73. ed When attaching removing and replacing panels and parts during vehicle repair wir ing often has to be disconnected It is for this reason that connectors are fitted to sites with wiring to enable disconnection Most connectors are made of plastic so handle them with care as they can be dam aged if handled too roughly To ensure smooth re connection when disconnecting wire attach a sticker or label so that you can identify where it is from Removal and fitting of parts 8 10 5 Air bags Air bags are adopted to improve passenger and driver safety They are designed so that they will deploy upon detecting impact Since pyrotechnic devices are used to inflate air bags they must be handled carefully The driver s air bag is stored in the steering wheel pad and the front passenger air bag is stored in the dash board If there is damage or deformation occurs in the sensors air bag module air bag control unit pretensioner and harness replace with a new product Use a digital circuit tester when checking air bags Do not use an analog circuit tester as the small amount of current inside could deploy an air bag Disconnect the air bag connector or remove the battery since an air bag may deploy unexpectedly Removing and installing air bags must be done with the utmost care Refer to the service manual when doing this and also if they are to be discarded W Follow the manual when working on air bags 6 Types of grease
74. ed from the front wheels via the suspension In front wheel drive vehicles the front body also takes the weight and drive force of the differential gear and drive shaft Consequently members and reinforcements have a dual hanging rack structure and the various joints also have a robust structure made by adding reinforcement The underframe members of front wheel drive vehicles are thicker than those of rear wheel drive vehicles and sometimes the toeboard joints have complex shapes The role of the front side frame is to absorb and distribute energy upon impact The front end has a significant amount of open space for the mounting of the radiator and headlamps Cross members are fitted underneath and rather detailed upper members above the front end At the sides there are lower side members underneath that support the engine and suspension and from the wheel apron it is covered by the suspension brackets which are fitted above the shock absorbers The upper member is incorporated and reinforced above the apron parallel to the upper member There is a toeboard connected to the floor on the passenger compartment side of the front body Members and reinforcements are welded and take up a large area and are combined with reinforcing materials In front wheel drive vehicles attachment rigidity is enhanced by placing side members from the bottom of the toeboard to the floor In some cases a sandwich structure using asphalt sheets is used to effectively ab
75. elder in full the name is often shortened to stud or stud weld When this method of pulling was first devel oped a thin rod that is a stud pin was used to gain leverage Today washers or shaped Mainan washers are commonly used Sheetmetal The principle is the same as that for a spot welder A weld is made with the resistant heat generated when a strong current is dis charged through a narrow area Consequent ly there are spot welders that can perform this function Although stud welders are commonly used because they are compact lightweight and simple since a stud welder does not have the power of a spot welder it cannot make proper welds 3 Pulling tools 1 Slide hammer Studs and slide hammers dent pullers are typical tools used for pulling Force is applied by the reverse action when the weight in the middle is moved Slide hammers come in a variety of lengths and with a variety of weights Select a slide hammer according to the site and extent of the damage Since the head is replaceable you can choose the appropriate attachment for the job such as a hook to pull wash ers and stud attachments and hooks that hook on to the end of panels If you use a stud puller with an electrode you won t need a slide hammer and stud but it can only be used to pull out one site z ech hal External panel repair 5 10 2 Lever type pulling rod Clamp a stud pin or washer in the center brace b
76. ems in the surrounding area as these welders produce naked flames Health and safety measures 1 8 4 Electrical work When doing wiring or other electrical work make sure the ignition switch is turned off and remove the connector to the negative terminal on the battery If there is a risk of the generation of static electricity do not touch the control unit connector or other similar parts Either use an anti static electric cord or start work after removing the static electricity by touching earthed metal W Remove the connector from the negative terminal on the battery before starting work 4 Health and safety related to painting work 1 Body filler Coming into contact with sanding dust produced when applying body filler after body repair harms respiratory function causing pneumoconiosis etc Use a dust mask when applying body filler Also use a sander that collects dust However since the use of a dust collection sander alone will not completely take care of the body filler dust work in a place with a dust collection system that suctions dust from the floor and wall surfaces When cleaning after sanding wear a dust mask and lower the pressure of the duster gun used for blowing so that the dust does not scatter over a wide area W Be careful with dust when using body filler e wl G TY Gels ust mas Dust ik Gi i collection sander Dust collection hose Grating of dust collection device mT Heal
77. epair work but it will cause additional deformation W Role of anchoring Adequate force cannot be applied without firm anchoring Repair of the underframe 9 7 2 Basic anchoring methods Basic anchoring is combined with setting up the body alignment system Normally the flanges under the side sills are anchored to the equipment using underbody clamps or special clamps for particular car models The body is anchored in four sites front back left and right The four clamps must be connected so that strong force is not applied to one site only Though vehicle models vary because with the floor system the anchor sites are apart from one another the underbody clamps are con nected with metal tubes shaped like a hanging rack They are not connected in bench or platform systems be cause the anchored sites and the bench are close If there are no flanges under the side sills create anchorage by welding on a thin panel or use a special anchor adapter available for each model In cases where the frame is separate like for a truck the frame and body are anchored separately Anchoring is also difficult if there is damage to the side of the body Anchor the undamaged side as normal and add anchor points at the front and rear to disperse the pulling force W Basic anchoring Side sill For the floor system the four anchor sites are connected in a double cross Pulling direction Set in a way that the direction of th
78. er bracket PP GF30 Com Boysi F handie 1 Hook cover Center lower bracket 5 O o O mm Jeer ront window molding Door mirror Body 2 Rear gate opener switch PP GF35 Outer cover Splashboard urbo grille E Mirror housing Rear wiper 10 Side indicator lamp Wu gt n Housing 11 Side spoiler 12 Rear spoiler Body High mounted lens High mounted housing W List of plastic reference symbols TABS acione butadiene styrene le o o ao C ms acmiontrie etnyiene ene gt 0 o T nl epom Etnviene propylene diene monomer ueber l Pame Poyamiderpoivphenyeneemer a 1 gem St Poiybutyenetereptthalte Io Im E E Polymethyl metacrylate x 80 rom eoa OO o a S PPP 1 Polypropylene 80 Polypropylene containing 20 of the glass fiber Polypropylene containing 30 of the glass fiber Body materials 3 16 8 Glass Various types of glass are used for the front windshield rear window and doors of automobiles Standard glass has had silicon Si soda NaO found in ash and caustic lime CaO added to it Colorless and transparent it is also resistant to acids and alkalines Using a safety glass in automobiles is obligated Safety glass must not cause injury if broken and must enable a certain field of view 1 Safety glass There are two types of safety glass There is reinforced glass with increased strength and laminated glass designed to lower danger when it breaks
79. er grit size than paper used for sanding sheetmetal The surface of aluminum soon oxidizes and though no further corrosion occurs paint does not adhere well to this oxidized film Consequently carry out surface preparation straightaway 2 Repair work Only sites in aluminum alloy panels with elastic deformation can be repaired by panel beating Repairing sites with plastic deformation is very difficult Strength is also lowered as a result of hammering and repeated pulling Hammers leave marks and there is con siderable stretching Therefore it is preferable to use a wooden or plastic hammer Also when an aluminum alloy is in contact with iron the aluminum will rust as a result of being in contact with another metal An aluminum alloy may rust because of iron powder adhering to tools used everyday for sheetmetal There are stud welders that have special aluminum pins for use on aluminum alloys The increasing use of alu minum alloy panels has seen the development of more and more equipment for aluminum alloys and most parts that are replaced can be repaired 3 Heating When working with aluminum apply moderate heat as aluminum can break if force is applied under low tem peratures The right temperature is roughly the same as when you touch a surface wearing a heavy duty cotton glove and it feels hot Aluminum alloys are good conductors of electricity Since the heat of a heated area spreads make sure that only a small area is heate
80. es or the end of panels They come in various shapes and sizes and can be used for a wide range of sites Vice clamps Because vice clamps have a large throat they can be attached to the body over an obstacle Vice clamps are used in areas where universal clamps cannot be used such as an edge with a box struc ture like the roof and floor and for clamping a pouch panel that uses service holes They are also known as C clamps because of their shape Special clamps These are clamps with shapes made to fit the body and panels They can be used only on specific sites They include blade clamps used for bolt holes in struts and narrow clamps used on the roof rail Repair of the underframe 9 21 Because of the wedges as the application of the forces becomes greater so is the force of biting into the panel As you apply more forces the teeth will bite into the panel For strut tower For fastening the body floor type a set of four Repair of the underframe 9 22 2 Clamps and pulling direction Clamps are designed to be pulled front to back up and down and right to left The pulling direction is determined by the structure of the clamp A clamp cannot be pulled in any direction The extended line of the pulling direction must pass through the center of the teeth If this is not exact moment could cause the teeth to slip and the clamp to break This precaution applies to every type of clamp W Corr
81. essed air and for which human strength is used The func tions of tools are mostly based on human hand movement They can be divided into three categories according to their function Namely there are tools that twist grip and cut 2 Twisting 1 Spanners and wrenches These are mainly used to tighten or loosen bolts and nuts They are used frequently There are spanners that are used to clamp the head of a bolt in a U shaped opening part ring spanners that are used by applying force to the whole area surrounding a bolt and a wheel brace type wrench that covers the head of a bolt A socket wrench is the same but it doesn t have the shaft a wheel brace type wrench has to cover a bolt They come with attachments such as different size sockets handles with a ratcheting mechanism and hand held shafts 2 Screwdrivers Screwdrivers are used for tightening and loosening screws They have slotted and crosshead or Phillips heads and are also classified according to the type of handle they have These include standard stubby and feed through handles Mi Hand tools Wheel brace Spanner type wrench Closed wrench D Crescent wrench Socket wrench Screwdrivers and others Removal and fitting of parts 8J 3 3 Gripping 1 Pliers In addition to ordinary pliers used for bending and cutting wire and iron sheets there are needle nose pliers with a thin tip circlip pliers and linesman pliers that are handy fo
82. et or a special protective cover 1 Prevent dust when sanding using a sander etc Prevent areas beside the repair site from being dirtied by dust generated when sanding paint or body filler Be particularly careful with regard to the passenger compartment and engine bay Protect the surrounding area us ing sheets covers and masking materials 2 Prevent interior fittings from getting dirty Prevent dust from adhering to the seats steering wheel and other parts of the passenger compartment by pro tecting them with plastic sheets and covers 3 Prevent sparks during welding Protect the vehicle body from sputters and sparks during welding by covering it with fire proof sheets cloth and paper 4 Protect the surrounding area when making body repairs and treating the substrate When making body repairs or treating the substrate protect the surrounding area by attaching masking tape or plastic tape so that the sander does not damage the pinstripe or other nearby parts Health and safety measures 1 6 2 Prevent fires and explosions Many pieces of equipment used for body repair can easily catch fire or explode Be extremely careful when han dling such items 1 Gasoline When siphoning gasoline be sure to comply with fire regulations Work in an area with good air flow and warn nearby workers Do not use a plastic pump or tank that generates static electricity when siphoning or for storage Store the siphoned gasoline in a
83. event dust from getting into the eyes and auto darkening helmets worn when welding Safety glasses protect the eyes not only from paint and body filler dust but also from metal powder when cutting panels and from sputters when stud or spot welding The rim adheres to the skin thus preventing dust and other matter from getting inside When MIG welding while making body repairs use a welding helmet and not an auto darkening helmet Health and safety measures 1 3 5 Dust masks Wear a dust mark so you don t breathe in paint dust particles metal power or welding fumes Dust masks are mainly worn when using body filler following panel work There are masks that contain activated carbon Replace with a new one when use reaches the time limit for use 6 Face shields Faces shields protect the face from metal power and from sputters when welding Although safety glasses seal tightly dust can get into the eyes through gaps This risk is lowered by using a face shield and safety glasses together Some face shields also serve as welding masks 7 Welding helmets auto darkening helmets Welding helmets protect the eyes and face from strong light and ultraviolet light when MIG welding There is a hand held type and a type worn on the head There are also auto darkening welding helmets that use a liquid crystal filter Health and safety measures 1 4 8 Ear plugs ear muffs Ears should be protected from loud noise such as t
84. ever it does take time to set up the jig Portable bench and bench placed on a hoist 4 Platform system This is also known as a drive on system because the vehicle is driven on to the work platform The pulling system and anchoring system are integrated and setting up requires a certain amount of space Many of these systems are made in North America To set up the platform is tilted so that the end is at floor height and the vehicle is driven or pulled by a chain onto the platform Because the vehicle is around one meter off the ground it makes working on the suspension easy Platform tilts and moves up and down 5 Other systems Other systems are basically variations of the floor jig bench and platform systems Some platform systems have a scaffold birdcage that encloses the entire vehicle These systems enable pulling from many directions Some systems combine a jig bench with a platform or floor system Simple floor systems with only anchoring parts can be used in combination with separate measuring and pulling systems The advantage of this system is the low initial cost Repair of the underframe 9 6 6 Related equipment In addition to the functions of anchoring measuring and pulling body adjustment and alignment systems come with a variety of other related devices and equipment Clamps are used to grip panels and there is a wide variety of shapes owing to the variety of damage sites and conditions There
85. g ratio of hardening agent is 100 2 3 Measure using an accurate measuring apparatus W Types of putty and filling performance Filling performance Surface condition Main applications Deep dents Metal sheet putty to 50 mm Coarse Sections subject to force Intermediate type to 30 mm Fairly rough Surface finishing Extremely soft Repairs of minor deviation These are general examples and values vary according to product 9 Types of sanders Use a double action sander orbital sander straight line sander etc for plane grinding the putty W Types of sanders Double action sander Long orbital sander Short orbital sander Straight line sander External panel repair 5 13 6 Beating using a hammer and dolly 1 Principles of repairing with a hammer and dolly 1 How to handle a hammer The way you hold and beat a hammer when repairing panels is different from beating using a chisel Even when repairing panels there are slightly different methods such as roughing out bumping and finishing The basic way to hold a hammer is to grip the end applying force with your little finger and gently holding it with your fourth finger and middle finger To stop the hammer from swinging sideways lightly press your thumb and index finger against the side It is important not to grip the hammer too firmly Grip the handle the moment you hit the panel The basic rule when using a hammer is not to use force but using your little
86. he noise of hammering the setting and re setting of equip ment and cutting noise when using air tools to cut panels If ear protection is not used when engaged in repair work for long periods noise and wavelengths not audible to the human ear can harm hearing and in some causes cause deafness There are ear plugs that are easily inserted into the ears and ear muffs that cover the ears 9 Gloves Work gloves heavy cotton welding gloves gloves for handling solvents high voltage insulating gloves Wear gloves appropriate for the particular task Use heavy cotton gloves when performing general tasks There are slip prevention cotton gloves that have a rubber coating on the palm side and high strength gloves that use Kevlar protection Avoid using cotton gloves when drilling because the tips can get caught Gloves made from animal skin are suitable when welding or repairing the underframe There are also solvent resistant gloves for use when handling degreasing agents and paint and special rubber gloves for use when working on high voltage sites W Use of protective equipment Head gear Safety glasses Dust mask Various types of gloves Welding 7 helmets Safety boots SIN Health and safety measures 1 5 3 Precautions 1 Protect bodywork and interior and exterior fittings Bodywork can be smudged and scratched during body repair work Prevent this by protecting the area around the work site Use a she
87. he time of the second oil crisis in 1979 as a means of improving fuel economy and reducing vehicle weight Since it has high tensile strength and a high elastic limit thin sheetmetal maintains the same strength as standard sheetmetal Accordingly when it is used for body panels it is thinner than standard sheetmetal 4 Vibration damping sheetmetal Vibration damping sheetmetal is made by putting plastic between two sheets of sheetmetal This type is also called a Sheetmetal sandwich sheetmetal panel It is used for the toeboard etc PP nylon asphalt sheet etc because the middle plastic layer absorbs external vibrational Sheetmetal energy It also reduces noise 5 Sheetmetal characteristics 1 Plasticity and elasticity When sheetmetal deforms due to the loading of force deformation occurs in two ways There is deformation that is recoverable when the force is released and deformation that is not recoverable The recoverable type is called elastic deformation and the unrecoverable type is called plastic deformation Only elastic deformation occurs when the force loaded to sheetmetal is weak The amount of deformation increases in proportion to the amount of force that is loaded Plastic deformation occurs when the force exceeds a certain level When loaded force exceeds the elasticity of the sheetmetal the degree of force at this point is known as the elastic limit This is because creep occurs in the sheetmetal s internal structu
88. he workpiece is too far the distance from the wire tip will also be far This will reduce the current which will result in shallow penetration Conversely if the distance is too short the large amount of current will result in deep penetration Accordingly if you make allowance for this you will be able to weld panels of different thicknesses without having to adjust the current 3 Alignment Plug weld Position the tip of the wire in the nozzle so that it is perpen dicular to the center of the hole being welded If it is not in the center there will be insufficient penetration to the lower panel Seam weld Put the wire tip in the middle of the bead The torch should be ata 5 20 angle to the direction of the weld Fillet weld First soot weld in a way of plug welds leaving a certain distance apart and then weld in a way of seam welds to fill up the gap 9 Quality check To check whether or not the weld is correct use a panel offcut making it the same thickness etc and check using a lapped splice Check the size of the weld diameters on both sides and then conduct a twist test The diameter of a plug weld should be 8 10 mm 2 4 mm on the rear panel and should be raised 1 2 mm Handling of welding equipment 9 W Distance from torch gf Tip Nozzle Extension Y CO2 Wire Panel W orch angle 5 20 W Plug weld diameter 8 10mm 1 2mm 2 4mm Handling of welding equipment 10
89. her side of the floor pan In models that have a trunk a panel separates the passenger compartment and the trunk Quarter panels are constructed with an inner and outer panel and the inner side is joined to the rear arch which forms the wheel housing The rear floor pan is joined directly to the passenger compartment floor The rear side frame on the other side is thinner and smaller than the front side frame This is because it does not require the same strength as the front Body construction 2 11 W Rear body structure and parts E High tension steel Rear floor front pan 7 Spare tire bracket 13 Rear floor side 2 Rear floor rear pan 8 Rear skirt 14 Rear floor cross member C 3 Front side upper member 9 Front floor side member 15 Rear floor cross member B 4 Rear side upper member 10 Rear suspension bracket 16 Rear floor cross member A 5 Rear of rear side upper member 11 Rear side sill inner 17 Tail gate 6 Spare tire reinforcement 12 Rear floor side member Refer to the diagram of the center body for a drawing of the side panels Body construction 2 12 Body materials 3 1 Chapter 3 Body materials Contents 1 Types NEE EE 2 2 Properties Of Metall cccccccccseeeeeeeeseeeeeeeeeeeeaeeeeeeceeeeeeeeeaeeeeseeeeeaneeaeeseeneeseeeaneesgeseeaenaeenaeesegeeseneeeeneeesaees 3 ae Ommon e ee aane O 3 2 Mechanical DroperlleS seen a eee ene nee one en E E et rn ee eee eee ere ee eer 4 3 From
90. ht curves Rubber applicator Body surface Putty Sheet metal treatment 6 10 Drying putty Even when drying naturally putty does not take much time to dry as at 20 C it will dry in around 20 minutes An infrared type drier can be used to fasten the drying process However care is needed as rapid heating and ex treme temperatures can cause paint to crack or peel Adjust the temperature by placing some distance between the drier and the site If the temperature is 5 C or below drying will take longer Not only heating up the body or the putty but also force dry instead Putty becomes hot when it is reacting Thick areas will dry first because drying is hastened under reaction heat of 100 C or more Therefore check how the paint is drying by scraping a fingernail across surrounding areas where the putty is thin This shows that sites with thin putty have poorer adhesion than sites in the middle Because high tension steel is not thick it is possible that shrinking or distortion can occur as a result of necking when the putty dries However there are putties with less solvent and those in which another substance swells to compensate for the solvent evaporation 4 Sanding putty Sanding putty consists of three steps rough sanding plane grind ing and scoring When applying the same putty or polyputty scuff after the putty has been smoothed Plane grinding is the hardest technique and ultimately is the domain of a
91. ies from the iron and adding necessary elements 3 Ingot making Blooming Steel is cast by pouring melted steel into casts ingot making and rolling it into thick sheets 100 300 mm thick blooming while it is being heated These sheets are called slabs 4 Hot rolling The slabs are heated ferric oxide is removed from the surface and the slab is rolled once into a thickness of 25 40 mm the surface is cleaned once more and the steel is rolled into the required thickness This is how hot rolled sheetmetal is made 5 Acid cleaning Ferric oxide is removed from the surface of hot rolled sheetmetal by washing it off with acid Body materials 3 6 6 Cold rolling Cold rolled sheets are made by rolling steel to the required thickness at room temperature 7 Annealing The structure within the steel which changes during rolling is heated to between 650 C and 700 C to get rid of distortion 8 Temper rolling Surface finishing is done by lightly rolling the surface This completes the steel sheet manufacturing process 4 Types of sheetmetal 1 Hot rolled and cold rolled sheetmetal Sheetmetal rolled at temperatures between 800 900 C is called hot rolled sheetmetal Hot rolled sheets that are rolled once again into thinner sheets at room temperature is called cold rolled sheetmetal Most sheetmetal used in automobiles is cold rolled This is because compared with hot rolled sheetmetal it can be rolled to th
92. if the residual force from the accident in the deformed site is released while it is being aligned springback will decrease Don t pull once Pulling force not only corrects the deformed area but also pulls normal areas Consequently as long as the dam age is not too minor instead of applying a huge amount of force all at once correct the deformation by pulling a little and hammering slacken the force to check the springback and then apply the force again If strong force is applied all of a sudden the lower elasticity in the deformed area could cause cracking W Pulling pointers pf i Pull while hammering Pull a little further by taking the deformed sections springback moving back into account Repair of the underframe 9 26 Handling of welding equipment 1 Chapter 10 Handling of welding equipment Contents 1 Welding methods and systems n nnssnunnssnnnnnnnnnnnnnnnnennnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnennennnnnn ennenen 2 2 SpOt E Dn e EE 2 KEREN Age 2 PA EEN tee 3 EE cee terres t igen eee E AA E deat ua cutest eel dine sue E A E E E S 3 4 Welding ee inter et EE 4 BA geleet Ee TEE d OEPS eebe EN 5 3 MIG ANNI WEE 6 1 Principles and characteristics EE 6 ESUD eea E E EE EEE A E E E EE 6 ECH SE 7 4 Weld wire Deet En EE 7 SCH VV VIG BO CGI WEE 7 HE lut E 7 ZANGO e EE 8 sy Gro e te Eet TE 9 FOU OREK ee 9 10 Safety e EE 10 4 Oxyacetylene gas welder dE 11 Handling
93. in the door When pulling near the trunk add a heavy rod to the part where the trunk opens Repair of the underframe 9 9 4 Setting adjustment and alignment equipment 1 Setting floor type adjustment and alignment equipment Assemble the anchoring system over the floor rails and anchors and set the damaged vehicle Although this will vary slightly from model to model first move the vehicle to the prescribed position If the vehicle cannot be driv en use a trailer or tow truck If using manpower use three or more people and designate one person to monitor the surrounding area If the steering wheel or brake can be used move the vehicle after checking them Place damaged parts in a wide corridor transport the vehicle to the prescribed position of the rails and anchors and first attach underbody clamps to the underneath of the side sills Sites near the jack points listed in the service manual are suitable locations for the clamps Then install the piping that connects the front back and right and left Leave the anchor bolts in place Next assemble the anchoring system in line with the underbody clamps and fix it to the rails If you are able raise the vehicle using a jack or the hoist that comes with the adjustment and alignment equipment When using a jack set up a rigid rack by jacking the front and back separately A rigid rack can be omitted if work underneath the body is not necessary Adjust the positions of the underbody clamp
94. ing sheetmetal plated on one side only it is usual for the plated surface to be facing the inside of the body 2 Corrosion resistance and handling Sheetmetal is made corrosion resistant by first covering it with a layer of zinc plating which prevents direct contact with the air thus making it difficult for rust to form Next if zinc and iron are present under the same conditions the zinc will rust while the tron will not Zinc rust does not penetrate as deeply as iron rust and because it stops after forming a thin layer on the surface the rust will not penetrate the sheetmetal Zinc and paint have poor adhesion When the paint layer is removed by sanding when making repairs the zinc plated layer also comes off exposing the surface of the sheetmetal This renders the sheetmetal the same as untreated sheetmetal But there are occasions when paint adhesion can deteriorate because the plated layer remains on feather edged areas However paint used for repairs today is made to cope with zinc plated sheetmetal so repair work can proceed as normal However the removal of the zinc plated layer means that a vehicle no longer has the corrosion resistance it had when new Consequently meticulous rustproofing should be done prior to painting W Dual layer alloyed hot dipped zinc plated sheetmetal Zinc 90 re Zinc o or more Iron 10 d Double sided specification W Uses of zinc plated sheetmetal Ma Sheetmetal on which
95. inner thicknesses it has a clean surface and has good workability W Types of sheetmetal Hot rolled sheetmetal ZE g Classification according to manufacturing method Cold rolled sheetmetal Sheetmetal for automobile use General sheetmetal Classification according to strength High tensile strength sheetmetal In the Japanese domestic market sheetmetal is classified according to the following categories under Japan Industrial Standards Please refer to the corresponding standards for each country as required 1 Hot rolled sheetmetal Hot rolled sheetmetal for use in G3113 SHPH310 370 400 440 Sheet thickness 1 6 14 mm automobile structures Workable hot rolled high tension SPFH490 540 590 G3134 For forming steel for automobile use SAPH540Y 590Y Figures denote tensile strength 310 is a minimum strength of 310 MPa 2 Cold rolled sheetmetal C is for ordinary use Cold rolled sheetmetal SPCC SPCD SPCE D is for drawing E is for deep drawing For drawing and forming SPFC340 370 SPFC390 440 490 540 590 Workable cold rolled high tension For forming SPFC490Y 540Y 590Y 780Y 980Y steel for automobile use Low yield ratio type SPFC340H Bake hardening type SPCD and SPCE have a minimum tensile strength of 270 MPa and they are stretched 34 43 depending on the thickness of the sheet As a general rule SPCC is not tested for tensile strength unless a request
96. integrated welders the arms are heavier a certain degree of strength is required to hold the gun at the weld site The weight is relieved by using an overhead boom Continuous welding causes the gun to heat This is the reason some welders are water cooled or air cooled There are multi functional spot welders that can also be used to weld washer studs used in body repair Recently high quality welding has become possible using a system in which a computer controls the welding conditions appropriate for the purpose panel thickness and the material being welded W Spot welder components Pressure lever Pressure lever Transformer Arm Power l cord thin d VM 8 ant at ntrol unit Nes i Separate transformer type Timer control unit C Built in transformer type 3 Gun The arms on a welding gun must be able to press the electrodes against the workpiece no matter the location of the site Accordingly a spot welder comes with a range of arms in different sizes and shapes Use an appropriate arm for the site Most arms are pressurized and held using air Choose the shortest possible arm for the welding site 1 Electrode tips In line Electricity won t flow if the upper and lower electrode tips pressed against the workpiece aren t in a straight line This also means that the arms are parallel Strength is significantly reduced if the arms are on a slight angle W Electrode tips
97. ire pullers and chain pullers are used as tools that amplify human force in a pulling direction Both produce force by reeling wire or chain Although it is a person who reels the wire or chain a continuous large force can be used because the reel has a lever that mul tiples the force 4 Pulling systems Damage that hasn t affected the underframe can be repaired using pulling systems that use chains clamps hy draulic rams chain pullers floor anchors and rails The extent to which a vehicle is firmly anchored varies according to the size of the force that is to be applied 3 Three elements of force 1 Magnitude and direction Magnitude direction and point of application are the three elements of force Arrows are often used to express the magnitude and direction of force Magnitude is shown by the length of the arrow and direction by the direction of the arrow This type of representation is known as a vector When represented by a vector it is easy to imagine the composition and dispersion of force Composition can be thought of as a single force made from two or more forces applied from other directions Dispersion is the way in which force applied from a certain direction spreads and transmits W Methods of expressing force Dispersion of forces Composition of forces mm wem wm emm em mmm i e Magnitude of force Direction of force gt Point of application Point where force is applied Added force
98. is made by the customer The figures for high tension steel denote tensile strength 340 is a minimum strength of 340 MPa 2 Corrosion resistant sheetmetal Body materials 3 7 When iron is left on its own it combines with the oxygen in the air forming rust ferric oxide on the surface When it is left even longer the rust gets into the inside making it brittle It is for this reason that sheetmetal resistant to rust is made by zinc plating the surface Different types from a wide range are used depending on the model and part of a vehicle The main types are shown below 1 Hot dipped sheetmetal Sheetmetal is plated by dipping it in molten zinc This is called hot dipped sheetmetal By immersing the sheetmetal in molten zinc a zinc layer adheres to the surface Rather than a zinc layer on the surface that has high purity dual layer alloyed zinc plated sheetmetal that has two layers of a zinc and iron alloy is most commonly used This is because it has superior weldability and paintability Making an alloy that contains iron by making an alloy layer that is 90 zinc and 10 and overlaying it with an alloy layer that is 80 or more iron enhances paintability Both paintability and corrosion resistance are provided by creating a zinc plated layer containing a lot of iron and an inside with a lot of zinc Some corrosion resistant sheetmetal is zinc plated on one side only while some is zinc plated on both sides When us
99. is sufficient However when using a hydraulic ram or a chain puller the pulling force can move the vehicle itself As a result the force is not used effectively and depending on the direction it can be dangerous It s a good idea to use chains to stabilize the vehicle so that it won t move Attach chains to strong areas of the body an attach them to floor rails or other solid fittings in the workshop W Hydraulic ram set 5 Other types of related tools Other tools and equipment required when pulling panels are shown below 1 Disc sander A disc sander is used for removing paint and sanding the metal surface when work has been completed Use paper with a coarse grit of between P24 and 80 There are single action sanders used specially for removing paint Paint can also be removed using a variety of other tools including a sand blaster and special plastic sanders 2 Belt sander Use a belt sander for removing paint from small dents and narrow areas 3 File Files used on metal are included in body repair tool kits They are used more to identify unevenness in panel surfaces than as a sanding tool 4 Guide coat A guide coat is back powder that is rubbed on the repair site or a black aero sol lacquer paint that is sprayed lightly on the repair site Humps and dents in the panel surface can be identified by sanding the surface once the guide coat has dried 5 Air duster gun cloths degreasing agents These are u
100. ity inspection Appendices FUJI HEAVY INDUSTRIES LTD Health and safety measures 1 1 Chapter 1 Health and safety measures Contents 1 Safety Measures at work cccccceeeceeeeceeeeeeeeeeaeeeanecaneseeeeeaneeaeesaeeeaeseasecaseeeseseaneeasesageeeaneeasesaeeeeeeeeaeeneesogees 2 2 Use of protective gear espesteseg e stee n eege eebe 2 PC Tel Lt EEN 2 SCH E WE 2 SFU EEN 2 EE AOE EE 2 BREET 3 MOY ACS NiS ee E E 3 7 Welding helmet auto darkening helmet A 3 CE Uug Se E E E 4 9 Gloves Work gloves heavy cotton welding gloves gloves for handling solvents high voltage insulating Be e 4 Ba EE aeeoe E E E 5 1 Protecting bodywork and interior and exterior FITTINGS ccccseeeeecceeeseeecceeeeeeeseeseeeceeaaeessesaeeesssaageeeeeas 5 2 Preventing fires and explosions ssssssnssssnnnesnnrresnnrrernnrrersnrrersnrrrrsnrrrrsnrrrennnnrernrrrennrtrennrtreonrnrernnnnern nenen 6 3 Health and safety related to body FEH 7 4 Health and safety related to painting WOMK eege Sege GE 8 4 Maintaining a tidy workshop WE 9 Health and safety measures 1 2 1 Safety measures at work Various kinds of machinery equipment tools and materials are used in body repair work Body repair involves highly dangerous work including the generation of intense heat and strong light when welding and fusing dust and fires during sanding and the handling of panels and parts with sharp edges To protect oneself and preve
101. l from straight in front or from the side square on Mi The concept of pulling direction V Regardless of the directions of deformation the pulling Force is applied effectively Since forces are dispersed direction should be straight against the body structure Can be repaired even with stronger force is required small forces and there is a possibility of clamp slips and generation of deformations on the normal area Repair of the underframe H 25 2 Spring back When force applied by pulling is released the panel which should have been fixed compresses and moves back considerably This is because of elasticity in the sheetmetal and the deformed area has not been able to stretch due to work hardening of the deformed area Compression of a panel for a second time after force has been released when pulling is known as springback Repair work is more efficient if springback is minimized The following three points are important for avoiding springback Extra pulling Even if while pulling the panel has resumed its original measurements if you pull an extra once or twice even if there is springback you will get closer to the original dimensions Hammering while pulling Because a deformed area that has work hardened plastic deformation is stronger the deformation won t come out even if you apply force by pulling and a panel in another place will be stretched Hammer the deformed site while applying some force and
102. lar inner D pillar reinforcement Rear quarter center reinforcement Rear arch inner Front pillar outer Center pillar outer Rear quarter outer D pillar extension Rear quarter end Side sill outer Front pillar door reinforcement Side rail reinforcement Center pillar reinforcement Side sill reinforcement outer Instrument panel bracket Floor center cross member Front floor front member Floor rear cross member Toeboard upper reinforcement Front floor rear frame Body construction H 9 E High tension steel Front floor pan Side sill inner Front pillar lower inner Front seat rear cross member Front seat front cross member Hand brake reinforcement Front door Rear door Body construction H 10 3 Rear body The structure of the rear body differs according to whether or not there is a trunk lid Although the structure is similar to the structure of the front body there is a floor panel covering the bottom It incorporates the same im pact absorption structure as the front Because it is difficult to ensure strength in cabover wagons or vans a member rather similar to a ladder frame is welded to the floor Somewhat different rear body structures are used for models with a separate trunk hatchbacks and vans Basi cally there are quarter panels that incorporate the rear pillars at the side a rear skirt at the back end a rear floor pan that serves as the floor to the trunk and rear side frames welded to the ot
103. lding Use a drill to make holes Replacement of welded panels 11 7 2 Paint removal and rustproofing Remove any primer coated on the new panel and paint on the weld sites on the body side on both the front and back Use a belt sander Apply a welding rustproofing sealer to the area where the welded panel will be placed If there are sites requiring a coating of sealer that will be hard to get to once the welding has been done apply the sealer beforehand Before fitting compare it with the old part to see whether it has enough small panels such as reinforcements If there aren t enough and if the reinforcements in the old panel are not marked or damaged take them out and weld them to the new panel first Rustproofing weld sites 3 Number of weld points Although in spot welding the number of weld points also depends on the power of the welder and repair site increase the number of weld points by about 30 so that outer panels have 10 more weld points than a new vehicle and underframe panels have 30 to 50 more weld points Generally the number of weld points is in creased because power when spot welding is different from the time of manufacture In the underframe there are sites where panels are put on top of each other If the total panel thickness is more than 3 mm choose MIG plug welding in preference to spot welding When MIG plug welding the same number of points as on a new vehicle is fine In principle
104. ling where suction is used pulling that uses clamps pull ing that uses a slide hammer with replaceable head attachments for different sites weld pulling that uses plastic tools as well as studs Small dents are also massaged by inserting a tool in the gap and massaging the dent from the rear Choose the most appropriate method depending on the site of the panel damage and where necessary use a combination of methods W Panel beating methods Hammering gt With hydraulic equipment etc Beating gt Hammering beating out Sheetmetal work l Pulling gt Suction hooking clipping welded Dinging gt Dent 1 Ends of panels with openings Wheel arch Deformations at the ends of panels like the wheel arch which has an opening can be pulled by attaching a hook type attachment to a slide hammer Of course this can also be done by normal washer pulling and because you can reach your hand in behind you can also beat the deformation 2 Repairs that can be made from behind rear quarter panels etc At some sites like quarter panels the hood and trunk lid if you remove the trim you can reach your hand or a tool around to the other side Consequently in addition to pulling you can also do planishing where you hammer out the deformation 3 Repairs that can only be done from the rear Pulling is done when you can t do the work from the rear without removing the part such as for welded parts like
105. lly there are two processes One is applying putty to fill in deep damage and the other is to fix tiny dents on the surface and use primer surfacer so that the top coat will adhere well Sometimes the extent of the damage requires the putty work stage to be done in two stages Small dents on the primer surfacer can be repaired using finishing putty Painting the top coat is an important process as it affects appearance after repairs have been made The quality of painting is greatly affected by the entire paint film painting system including the primer coat 9 Attaching parts Bolted on parts removed at the beginning are refitted when all stages are completed Moldings and decals are attached at this stage Repair procedures LAT 5 10 Completion checks Check the appearance of the car and the wiring inside the engine room Check wheel alignment and whether the various parts are functioning normally If there are no problems arrange for the car to be delivered to the owner after cleaning the interior and washing the car Repair procedures 4 6 External panel repair 5 1 Chapter 5 External panel repair Contents 1 Scope of E A d e TEE 2 KE DOS SOF CCT FE ALI OI eege 2 2 Wels ry GING RT ue EEN 2 CSCIC CHING Tor dents and e ET e CN 2 4 Distinguishing elastic deformation and plastic deformation ccscccccesseeeeesesseeeceeaeeeeeseseeesseeeeeeeas 4 5 Panel beating methods for different repair sites
106. lude measuring using laser beams and the use of computers to read data on the positions of indicators set under the underbody that can make real time comparisons of these measurements and the correct dimensions 4 Jigs A jig is a tool used for aligning parts Jigs that WR Dedicated jig are used in alignment systems show the normal T positions of major body sites and parts There Cy wel or tity aU BL SE _ A are universal jigs and dedicated jigs Dedicated jig A dedicated jig uses attachments designed for a specific model They can also be used to hold the position of a new panel for placement and welding Universal jig A universal jig can be used for many models by altering the way in which the provided jigs are assembled The jigs are assembled by follow lz GN TAS paira ing the directions according to the body charts prepared for each model made by the manufac turer by taking actual measurements Each universal jig system has its own set of body charts Repair of the underframe 9 14 W Body charts 296 2 23 Copyright 2007 2 CAR O LIMER TWIGEN TOFO D su len 6Sea tax P ee D2 SSES EIN s Jk eh BEE Sokerin e 3 Subaru HisHi4e1 5670 GLOBALJIG LEGACY caps HH CAR O LINER Lk al Been AR og S i sch 3 kaf eet eet e ce BC ee HC reese LOODE ae Y Repair of the underframe 9 1
107. machine oil Replace cracked or deformed bolts and nuts with new ones Don t twist chains Chains which transmit force to the clamps play an important role in body re pair Chains of a size specified for the alignment system have some margin as far as strength is concerned They do not break as long as they are used nor mally However it is dangerous to use a smaller chain than the size specified or to use and old chain that has rust Using even a specified chain when it is twisted will apply undue force and even if it doesn t break suddenly its strength will be decreased Always make sure a chain is not twisted and protect it by occasionally applying some ma chine oil Repair of the underframe 9 24 5 Pointers 1 How to determine the pulling direction In the case of comparatively light front damage repairs can be made by following a certain method regardless of the condition of the damage Let s take the example of a vehicle that received an impact from the front on the left side on a diagonal The left side of the front body is pushed toward the rear while the whole vehicle is bent toward the upper right The damage stopped at the side member and the toeboard has not been affected Since the impact was from the front left on a diagonal one would think that the pulling direction is also the front left on a diagonal and that since the vehicle is bent slightly up to the right force should be applied in a slightly downward
108. measure deviation from standard positions with millimeter accuracy This equipment serves three main purposes Although some have a single function the systems were originally designed to have these three functions There are three main different types of system floor bench and platform drive on Pulling equipment This is used to pull and push parts of the body freely with a specified force Anchoring equipment This stops the body from moving from its position when force is applied What is more vehicles can be anchored and released quickly Measuring equipment This equipment gives accurate measurements and comparisons without needing plenty of experience Repair of the underframe 9 4 W hree requirements ko Fastening device Pulling Measurement device device Fastening This will set the vehicle firmly device as the applied force is effectively utilized Setting the vehicle L Resetting the vehicle Checking the degree of deformation Roughing out MITE Talal Checking distortions of the sizes and device conditions of the reconstruction Checking the degree of reconstruction This device generates effective force by using the power such as hydraulic device Pulling device 2 Floor systems Floor systems anchor pulling equipment and anchoring equip ment to rails or anchors embedded in the floor They allow independent use of individual s
109. mples of universal measuring instruments 1 Tram gauge The length of the tram gauge is adjustable and there is an indicator needle on the ends of each of the rods that can also be secured The rods have a measuring tape and weights and gauges from which the figures of the dimension between the two indicator needles can be read directly are most common A tram gauge is useful for measuring the distance between two points on the body and it is also easy to handle It is indispensable in body repair work This range is expandable Measure tape Indicator needle Points the measured position Repair of the underframe H 13 2 Centering gauge When suspended at the symmetrical points of the underbody it will automatically show the body s center line By looking through a pin from one end you will see the deflection of the body It takes a little time to learn how to look through the pin Other gauges that are suspended under the un derbody include those that use a plate to mea Deflection of the center is checked through the pin sure the distance using laser beams The center alignment Be ing does not provide figures it only allows you et to check alignment 3 Adjustment and alignment equip ment and measuring systems to the body Ke Hooks to be attached Although jigs are often used in systems that combine measuring systems there is a variety of other systems that are also used These inc
110. n methods are attaching a reinforcing panel to the under side of the join and welding and making a flange to lap the join In a flange operation there are various lines though this can also be remedied Because adhesives used for repair take time to harden the panels must be secured to a firm surface or clamped This can be done in various ways Methods include combining spot welding and rivets using special fastening clamps and combining spot welding and adhesive When repairing panels using the bonding method positioning must be precise and the panels must be securely fastened until the adhesive has hardened completely There are cases where due to a huge change in temperature the difference between the cut out sheetmetal and swelling or contraction of the filler after painting making the line visible as a result Ways to counter this include selecting an appropriate filler and thorough implementation of forced drying Long panels cut out and replaced are prone to distortion caused by heat There is also a higher risk of rusting W Example of weld bonding Attaching to the back of a panel Riveted i j 3 mm 50 mm interval Make a piece with the same shape for attaching to the back of the body side and the side of the part being replaced and glue using adhesive welding Spot weld the first of the two pieces to be worked 100 ma meral Fasten rivets on the surface of the second piece except line sections Joggling Make
111. n nne 4 5 Mandling air e E 5 6 Maintaining quality E 5 Quality inspection 13 2 1 Wheel alignment 1 Body and wheel alignment The suspension determines the position of the wheels In a unitized body the suspension is attached directly to the body or via a subframe Consequently if there is deviation in the body the wheels will also be misaligned When the repairs have been completed check the wheel alignment of vehicles that have had damage to the wheel apron and side frame The set values for wheel alignment are the same as those for a new vehicle If the tires or wheel sizes have been changed the set values will be different The values will also be different if the parts that make up the suspension are damaged or worn 2 Factors and testing The factors in wheel alignment are toe in camber caster and the kingpin angle Misalignment or tilt in the front rear vehicle axis is also an important factor that affects all four wheels Use a four wheel alignment tester under prescribed conditions empty vehicle on horizontal site to measure and test the wheel alignment If there is misalignment adjust while referring to the wheel alignment chapter in the Chassis edition of the service manual However there are occasions when realignment exceeds the scope of adjustment or adjustment is not possible for structural reasons This requires alignment of the body to which the suspension is attached Do this in accor dance with the
112. nchoring system if that section is weak it will not be possible to apply a large amount of force 3 The action of inertia When the same amount of force is applied it acts differently depending on whether the force is applied slowly or whether the same force is applied momentarily For instance if a certain amount of force is steadily applied to a stationery vehicle the vehicle will start moving in the direction to which the force has been applied However if a huge force is applied momentarily the area to which the force was applied will deform This is how inertia works In other words inertia means that a body in motion tends to remain in motion and a body a rest tends to stay at rest Inertia is in proportion to the weight of the body Force received by a car in an accident is momentary force Therefore even though a vehicle that is not anchored it will not produce moving force and as a result the body will deform In contrast force applied when repairing is applied slowly Consequently if the body is not firmly anchored the vehicle will move The force will also have a wider effect than the force did in the accident Inertia Heavier objects are more difficult to move and once they move you need larger force to stop them Repair of the underframe 9 20 4 Concentration and dispersion of force When force is applied at one site to a material made entirely of the same substance and which has a uniform shape the force
113. nd hammer can be used to remove the welded point Handling of welding equipment 10 6 3 MIG welding 1 Principles and characteristics In MIG welding the welding wire is the electrode and is melted by the heat of the arc within an inert gas shield It is also known as semi automated welding as when the switch is turned on the wire is automatically fed through TIG welding also uses the heat generated by the arc The electrodes are tungsten so they do not wear The arc produced by the electrodes melt the welding rod This requires the use of both hands The small torch used on one side only means that MIG welding can be used in a variety of sites Another feature of MIG welding is that it can be used to weld panels of unequal thickness A MIG welder is used for sites that are inaccessible for spot welding sites that require strength and for patches on panels Distortion is minimal and basic operation is rela W Principles of MIG welding tively simple A direct current power source of 200 V is used With switch ON Wire melts with spark Plug welds spot welds and seam welds butt the current flows to heat and drops onto emit the arc sparks the part to be welded welds are mostly used when repairing panels This will cause short Weldi i circuit of arc and thus Plug welds are made at sites that are inacces e arc discharge is stopped sible for spot welding A plug weld is made by _ With large c
114. ne projection measurements In Subaru body manuals the underbody is shown by plane projection measurements and the upper body is shown using linear distance measurements Linear distance measurements Linear distance measurements are taken by measuring the direct distance between two measurement points vehicle reference points They are easy to understand because they can be measured directly using a calibrated tram gauge However It s often not possible to measure the inside of the engine room if the engine is there Repair of the underframe 9 16 Plane projection measurements Plane projection measurements are obtained by establishing a virtual plane parallel to the body and take mea surements from an image of the body projected onto the plane In other words it takes planar measurements that do not take account of differences in height and width This is almost impossible to do with an ordinary tram gauge or measuring tape These measurements are useful when using a set body and alignment and measuring equipment that have a parallel measuring plane or lines A cord with an attached weight is hung from the measurement points and the distance between the places where the weights come in contact with the measurement plane is measured This is why some systems and measure ment systems come with indicator needles Using this method it is possible to get the required measurements even if there are obstacles such as the engine
115. nels are attached under pressure a strong cur rent melts the welding surface of the panels When the current is stopped pressure is maintained until the weld cools which strengthens the weld nugget One main feature of spot welding is that technically it is relatively simple and can be done quickly without much experience Because heat is applied to one site only the heat has minimal effect on the surrounding area thus restricting distortion W Principles of spot welding To be melted Applying pressure Tip Applying pressure Applying pressure Apply pressure on to the part to be welded of the lapped panels and they are adhered so that the current flows easily with the heat generated by the resistance Applying pressure Applying pressure Electroconductivity With pressure being applied apply a large current so that the contact surface of the panels is melted and welded together Power supply Applying pressure l Nugget Applying pressure Holding Even after applying current continue applying pressure until the welded part cools down so that the welded part nugget will be reinforced Handling of welding equipment 3 2 Components A spot welder consists of a welding gun arm with electrodes a transformer and a timer Some welders are integrated units where the transformer is built directly into the welding gun while some use a separate transformer Because in
116. nical parts but it is expensive Like iron it exists in the natural world combined with oxygen because they are bound firmly the manufacturing process consumes a huge amount of electricity Because pure aluminum is soft other elements are added to make an alloy heat treated aluminum magnesium and silicon alloys 6000 series are the main alloys used in exterior body panels Aluminum has excellent weldability and corrosion resistance There is also non heat treated aluminum and magnesium alloys 5000 series which have excellent workability Aluminum is also rust proof With a melting point of 660 C it is lower than iron s melting point of 1 536 C But because its tensile strength lowers when it is heated care is required Even though it is light its low tensile strength means that thicker panels are used It s a good idea to have an understanding of these characteristics when repairing aluminum alloy panels Due to its low specific resistance it is difficult to weld a stud with a conventional stud welder The surface of aluminum is easily damaged and attention also needs to be taken with welding and painting W Differences between iron and aluminum Melting temperature TO Melts without becoming red hot Weight per same volume 0 34 Weighs approx one third Thermal conductivity Has nearly twice the thermal conductivity Electrical conductivity Has nearly twice the electrical conductivity Body materials 3 13 7 Plastic Parts m
117. nking of metal that occurs due to temperature change It is an important task that has a huge effect on the finished quality 2 Detecting and preventing stretching Shrinking is a technically difficult part of panel repair A damaged panel has varying degrees of damage and most have a part that has stretched In restoration it is necessary not to make the stretching any worse and to keep it to a minimum In details do not apply stronger force than necessary when beating do not keep repeatedly beating the same spot and make the repair as simple as possible Often it is not possible to identify a stretched part from its appearance alone In order to find the stretched part either run your hand over the sheetmetal or press the metal with your fingers W Panel stretching When force is applied to metal it stretches and expands Even a stretched area that looks as if it has been Hammering will stretch the sheetmetal restored to its normal shape will rumble when you run your hand over it ER External panel repair 5 21 1 Feeling by hand Run the palm of your hand from the undamaged part of the panel over the part that has been repaired The part that has stretched will bulge slightly Sometimes parts along the press line or on the edges of a panel that have nothing to do with the repair will bulge This is caused by stretching of the part being repaired This will naturally correct itself when the stretching is fixed 2
118. nt accidents it is important to learn about safety measures and to wear protective gear suitable for each task Follow the prescribed methods for using equipment machine tools and materials Use the correct equipment machine tools and materials for each task and do not use equipment for tasks for which they are not designed Regular maintenance of equipment and machine tools and maintenance after use depending on what they are used for must be carried out checks cleaning lubrication as necessary etc Maintain a suitable body posture and use necessary supports 2 Use of protective gear The following protective gear is used when carrying out panel work 1 Clothing When engaged in welding work where sparks are generated wear a welding apron and arm and leg protectors Do not wear short sleeve summer clothing when welding 2 Head gear Head gear must be worn at all times for protection from sparks iron powder dust etc If the visor gets in the way due to the site you are working on or because of other protective gear you are wearing don t remove your head gear but wear it backwards It is recommended that helmets be worn when doing body work 3 Safety boots Safety boots prevent slipping the thick soles protect the soles of your feet from sharp objects and the steel caps protect toes from heavy objects The surface is resistant to sparks and other hazards 4 Safety glasses There are safety glasses that pr
119. oblems when painting Putty or polyputty used after body repair is a two pack base coat Place only the required amount of the correctly mixed filler and hardening agent on a mixing pallet and mix with an applicator When you need a lot of putty mix and apply it more than once Mixing a lot of putty at once will take time and the application will also take time Mix the putty evenly and quickly The primary agent of the putty will start hardening rapidly as soon as the hard ening agent has been mixed in Mix the filler without letting air get inside If air gets in it is possible that there could be problems with painting later on Spread the hardening agent over the putty rub it in and mix it by reversing directions until an even color is formed Mi Degreasing Wipe the site with a cloth containing a degreasing agent and then wipe with a clean cloth j Sheet metal treatment 6 9 Technique Putty is applied in three steps folding building up and smoothing First apply the putty with the applica tor upright as if lightly folding This will improve adhesion to the sheetmetal Next coat it holding the applicator at a 30 45 angle Apply a number of times as necessary for dents Do not apply thickly in a single application Air could get in or holes could form Lastly clean and put aside the applicator smooth the surface and get rid of the applicator marks Remove putty that has spilled over to the surrounding area
120. ocket wrench and bit ex Removal and fitting of parts 8j 5 2 Drilling and joggling tools 1 Air drill An air drill is mainly used to grind down welds There are also drills designed for spot welds that have adjustable depths 2 Spot cutter A spot cutter is used specifically for drilling a hole in spot welds without wearing the tip The cutter is attached to a spot drill 3 Punching tools Punching tools are used for drilling holes in MIG plug welds There are also manual punch ing tools 4 Flanging tools A flange tool is used to make a butt on a joint in a welded panel Some types can also punch holes while some come with different shaped tips used for crowns and corners 3 Cutting equipment 1 Plasma cutter Using a plasma arc and air the plasma cutter cuts even thick panels made of any type of ma SCH O terial It produces a clean finish on the cutting Q surface 2 Air saw This is an airpowered saw The saw blade moves up and down and there are low speed and high speed models The air chisel was the first airpowered cutting tool and was followed by rotary cutters and air nibblers The most commonly used tool today is the air saw which creates a clean cut Removal and fitting of parts 8 6 3 Removal and fitting pointers 1 Tires and wheels When removing and fitting parts refer to the service manual and body repair manual Below is
121. ody repair work can cause serious damage or injury due to the heavy items and large force handled Pay atten tion to the following to prevent serious damage or injury Securely fasten bolts nuts etc on repair equipment and check they are not loose When pulling be prepared in case the clamp should come off by staying out of the area where the chain or clamp is likely to land Attach a safety wire so that the clamp is restrained if it comes off Follow instructions for the use of jacks and hoists carefully and when going under a vehicle always support the vehicle securely with rigid racks etc 2 Using jacks When jacking up a vehicle or supporting a vehicle with rigid racks follow the instructions and weight limits in the service manual Check carefully to see whether the vehicle is stable or not When jacking only the front or rear make sure that the wheels are locked Do not leave a vehicle in a jacked up position W Vehicle is jacked using rigid racks 3 Welding work Providing that there is nothing wrong with a welder it will not cause electric shocks or catch fire However regular checks are essential Pay attention to the following when welding Gas produced when welding is toxic so wear a protective mask Looking directly at a flame when welding can at worst lead to the risk of blindness Always wear a welding helmet or safety glasses When using an oxygen or acetylene gas welder check there are no flammable it
122. of spanners and wrenches and the thickness of screwdriver shafts are designed to provide the ap propriate amount of force for the various bolts and nuts Consequently if they are lengthened using a pipe or other tools or too much pressure is applied not only the tool but also the bolt or nut you are working on could be damaged Mi How to handle hand tools Correct way to use O Set deep with the size matching to the bolt Set horizontally to the bolt Strong force should be applied to the pulling direction Wrong way to use Oy ts A be W Bolt and nut width across flat Width across a AN f width i diameter J vllat Size of the width across flat 14 mm Size indication Size ofthe width T fF 4 across flat 23mm AN g 2 Power tools Power tools driven by air or electricity are useful for reducing the amount of energy needed and are used to ob tain a tidy finish 1 Removal and fitting tools 1 Impact wrench An impact wrench tightens and fastens bolts while applying an impact blow It uses a hexagonal chuck The shank where the bits are attached comes in several sizes The most commonly used sizes are half inch 12 7 mm shanks used for wheel nut wrenches and the 3 8 inch 9 5 mm shank used for removing and fitting panels and parts 2 Air ratchet An air ratchet is used to quickly turn bolts in narrow places It can be used with a s
123. of welding equipment 2 1 Welding methods and types Spot welders and MIG welders are mainly used for replacing welded parts Welding using a spot welder the same method used in the manufacture of new vehicles is by far the more com mon method However because the performance of welders used for repair work is not as good as those used during production reliable repair such as increasing the number of welds is required A MIG welder is used for sites that require strength sites where spot welding can t be used and sites that require patches and spot welds Joins made using an oxyacetylene welder which used to be universally used have insufficient strength so are not used any more MIG welders are mainly used for aluminum alloy panels instead of spot welders As for plastic since most mate rials are thermoplastic use a welder made for welding plastic that generates heated air The welding rod should be made from the same material as the material being welded Rustproofing is essential when welding metal panels Make sure you apply an antirust agent used for welding before you start welding 2 Spot welding 1 Principles and characteristics Spot welding also goes by the name electrical resistance welding As the name suggests the joint section of the panel is melted and joined using heat generated by the resistance of the welding current through the panels Clamp the two panels using copper electrodes tips Once the pa
124. or or an alr powered hydraulic pump They are not the same as hoists used for maintenance and many are pan tograph hoists that are part of a body repair system By raising a vehicle the repairer does not have to assume unnatural postures while working on the side or underneath a vehicle The basic rule is not to crawl under the hoist and to check for safety before and after use 2 Garage jack A garage jack uses manual power or air power to raise a vehicle Do not go under a vehicle that is raised on a jack Be sure to support the vehicle with a rigid rack and check for safety 3 Air compressor Most power tools are driven by compressed air A compressor operates using an electric motor Al though it depends on the number of repairers and the number of tools being used the compressor should be set at 1 5 2 0 HP per individual repairer Since work stops if the compressor shuts off a re liable daily backup and maintenance system is re quired including all of the air piping 4 Power supply unit A power supply unit is a power supply system that integrates power supply air and dust suction ducts Many have a light that illuminates when the power is on The unit is installed on the ceiling a pillar or on a wall and cords and hoses can be pulled from the unit as needed 5 Headlamp tester A headlamp tester measures whether the illumi nation range of the headlamps confo
125. ot welding are the weld current time pressing force and tip diameter These vary depending on the thickness of the panel These criteria can also vary due to the characteristics of the spot welder being used Optimum results can be ob tained by inputting data such as panel thickness so that the welder automatically controls these values 5 Conditions of use 1 Surface conditions of the joined panels There should be no gaps paint or rust in the surfaces to be joined The tips must be pressed tightly against the panel surfaces 2 Rustproofing treatment on the surface Treat the surfaces to be joined by applying a rustproofing sealer beforehand Rustproof sealers used for welding conduct current 3 Weld pitch When spot welding continuously current diversion will occur if the spacing pitch between the present site and next site is short Some of the current will be lost because it will try to reach the previous weld site where resistance is low Since there is not the expected level of current flowing the strength of the latter site will be lowered It is for this reason that you should weld while maintaining certain spacing Spacing between weld sites should be more than three times the diameter of the weld nugget Handling of welding equipment 5 W Weld pitch Pitch Current diversion will occur if the spacing pitch is short 4 Number of weld points Refer to the body manual for the locations of the spot wel
126. oth sides or the top of the circle and pull the lever The metal is pulled out using the principle of a lever Because it makes it possible to use a point to pull out only the corresponding surrounding surface it is a good method for beginners There are also air powered pulling rods Air powered Hand held type type 3 Suction puller A suction puller works by attaching a suction cup to the sheet metal When there is elastic deformation in doors and outer panels a suc tion puller can be used to pull out and restore the shape of the sur face quickly providing the pull point is appropriate 4 Hooks Force can be applied to a panel using just the hand by hooking a hand hook into a washer or a hole in the panel Hand hooks are use ful for repairing relatively light damage by hammering an area with plastic deformation while pulling an area with elastic deformation 4 Tower chain puller hydraulic ram A chain puller or hydraulic equipment is used not only for repairing the underframe but also for repairing strong areas in panels They are used when manual force or a the force of a slide hammer is insufficient A tower is a simple type that does not have the power of a floor type system and is used for pulling in combina tion with a chain puller or similar equipment However when more force is used to repair a panel it is also necessary to steady the body side When using manual force the weight of the vehicle on its own
127. ouch struc tures Reinforcing materials filled inside pillars must not be burned When working on a particular vehicle model for the first time make sure you refer to the service manual beforehand When making a rough cut for a patch leave a margin of an extra 30 mm on the body side Use an air saw or plasma cutter for cutting If using a tool that produces a lot of noise insert ear plugs or wear ear muffs Do not remove the panel being replaced until the dimen sions have been corrected 3 Drilling out spot welds Using a drill or a dedicated spot drill remove nuggets on spot welds by grinding Make sure you grind only the upper panel and not the lower panel A spot drill can be adjusted to the thickness of the panel Do not use an ordinary blade with a pointed tip Use an al most flat dedicated blade spot cutter When there are three layers and the panel being replaced is under the remaining panel go all the way through Use a MIG welder weld a plug into the hole in the remaining panel 4 Taking off the panel Insert a chisel into the gap in the panel on which you used the spot drill tap it with a hammer and take off Apply force in the direction in which you are taking off the panel so that the panel on the remaining side is not marked Also use a chisel and hammer to take off chips from the old panel that remain on the edge Lastly with a hammer and dolly repair any dents or bumps formed in the welded
128. paint technician Rough sand with a sander and do the last of the plane grinding by hand to produce a smooth surface A double action sander orbital sander or straight sander can be used for this There are different sizes and different models for different skill levels Use a double action sander or orbital sander with a high number of oribt diameter A sander with a large ec centric shaft has excellent sanding power The sander is moved differently depending on the work site and shape For flat surfaces don t move the sander in the same direc tion but move it back and forth right to left etc at various angles Use P120 180 paper For a slightly curved surface move the sander in a straight line at an angle to the vertical direction of the body A straight sander and long orbital sander are suitable for this In the case of a long thin repair surface it is best to work in a lengthwise direction when applying putty and sanding Press lines are treated the same as when applying putty Use masking tape to protect one side of the line while sanding the other Sanding the surfaces on both sides of the line will naturally produce the press line This method can also be applied to gently curved surfaces Sur face finishing can be done quickly by dividing the top and bottom in two sanding each part and lastly smoothing the middle Sheet metal treatment 6 11 M Technique for putty sanding Sanding flat surfaces Move the san
129. painting Because high tensile strength sheets can have the same strength as standard sheetmetal even though they are thinner they were initially adopted for large flat panels such as the hood and doors as a means of reducing weight Today however they have a wide range of uses including frames members pillars and reinforcements Some exhibit slightly different properties compared with standard sheetmetal with respect to the way they deform when damaged and when they are repaired Aluminum alloys and plastic are two other materials used for vehicle bodies Aluminum alloys with the same strength as sheetmetal is lighter and so are used to reduce the weight of vehicles Because the properties of aluminum alloys are different from steel they require different handling for body repair welding and painting Although plastic is mainly used for bumpers the front grille moldings and interior components plastic is also used for body panels Repair methods vary depending on the type of plastic and can require special tools and materials W Body materials Thin standard sheetmetal ranging in thickness from 0 6 mm to Standard sheetmetal 0 8 mm are used depending on the section high tension steel with the same thickness as standard sheets high tension steel have higher strength Corrosive resistant Sheets are made rust resistant by zinc plating either one side or sheetmetal both sides Aluminum alloys used Aluminum alloy panels that
130. panels IMPAEZA Vehicle reference values and dimensions Arrangement reference values Weld points and cut lines for replacement of each panel 2 Service manual Body Air bag removal and fitting diagnosis Removal and fitting of interior and exterior fittings 3 Service manual Chassis Adjustment of suspension and wheel alignment Appendices 6
131. part 2 Preparation for fitting 1 Treating panels After removing the panel use a belt sander to smooth any spot weld traces on the panel to be used Repair damage to spot welds or pierced sites that occurred during removal using MIG welding Replacement of welded panels 11 5 Smooth using a belt sander Replacement of welded panels 11 6 2 MIG plug weld holes Make a hole about 6 mm in diameter in the upper panel at sites that are to be welded with MIG plugs Use an air drill or punching tool Using a belt sander remove paint film on the body side and new part side taking off more paint than the size of the hole 3 Preparation for the new panel When cutting out to make a patch cut it out with an air saw or plasma cutter leaving a margin of around 30 50 mm on the body side 3 Fitting 1 Trial fitting and final cut Trial fit the new panel by clamping it in place If the panel needs cutting place the two panels one on top of the other and cut simultaneously using an air saw If this is not possible cut in line with the final measurements Do this gradually not in a single step In the trial fit check the measurements and fit any related panels adjacent panels and bolt on panels and looking at the whole arrangement determine whether they are aligned Using a tram gauge compare with the reference values in the body dimension diagram If the position is fine take it off and prepare for we
132. pected directions if thought is not given to the anchored points and the direction of the force Moment Center of gravity Moment Center of gravity en Sp gp ep vm Center of gravity 6 If force is applied to a site away from its center of gravity moment will be generated and a rotational force is created 4 Clamps 1 Structure of clamps Clamps are used so that force can be applied when pulling the body Although clamps are generally tools used to hold something or to clasp some thing clamps are used in alignment work as tools that are attached to panels and to which force is applied With the exception of special clamps clamps used for pulling have two rows of teeth that clip onto a panel or flange The teeth are pressed against the panel by tightening a bolt If the pulling force is correct the more that force is applied the more the teeth will take on a shape that sinks into the body The bigger the area of the teeth the greater the amount of force that can be applied Although the part that clamps the body is similar for every shape of clamp the clamp itself comes in various different shapes This is so that they can be attached anywhere on the body There are clamps that can be used universally in various dif ferent places and those that are for use in a special single site Clamps can be divided into the follow ing broad categories Universal clamps These are attached to flang
133. progress Easy to repair when heated Temperature limits are 200 C 6000 type alloy and 250 C 5000 type alloy Excessive heating deteriorates strength Use a radiation thermometer Use a dedicated MIG welder Spot welding is impossible because of their electroconductivity Use aluminum wire and argon gas Primer for aluminum Repairing aluminum alloy and plastic panels 12 4 2 Repairing plastic panels In some instances plastic panels are used for the rear gate W Rear gate R1 RJ Examples of plastic bumpers often requiring repair are listed below 1 Minor damage Wash damage affecting the luster caused by moderate contact sand with P600 paper and then gently polish the damaged area 2 Major damage If the bumper has scratches wash with water and then cut off any protrusions with a knife Sand with P120 600 paper Repairing aluminum alloy and plastic panels 12 5 3 Cracks and holes When repairing holes and cracks fill the holes or cracks with a welding rod made from the same material using a welder used for plastic parts heat gun After degreasing cut a guide slit into the hole or crack and cre ate a V shaped groove using a knife or sander Sand the surface of the groove using P60 paper degrease and clean Using a heat gun and a welding rod of the same material fill in the groove while melting the damage site at the same time Leave until it returns to room temperature Hold the he
134. r Mf Hydraulic units and work the fluid to which pressure has been added by manually pushing a pump amplifies its force in a piston in a hydraulic ram A hydraulic ram can be used for a variety of purposes centering on pis tons by fitting new pipes and changing the attach ments on the tip Its many uses include widening a spot that has been pushed in raising an area that is sagging and stretching a panel that is compressed But because of its force it is often used to repair sites on the frame such as frames members and pillars When a hydraulic ram is about to release a large amount of force the stroke ram displacement de creases As a result there is a limit to how much manual pumps can be used when the pushing dis tance is long and you want to increase force An air pump driven by compressed air is used in such cases With the flick of a switch you can get the required force and stroke Most hoists and jacks used for repairing vehicle In reality the pulling direction will not change as shown in the diagram bodies are air driven hydraulic rams and have ba sically the same structure as those used to repair panels On its own a hydraulic ram can virtually only pro duce force in a pushing direction However by combining a ram with chains it is possible to pro duce force in a pulling direction Repair of the underframe 9 18 3 Chain puller Not only hydraulic rams produce large pulling force W
135. r removing the coating of plastic wire and for attaching connectors 4 Cutting 1 Saws In vehicle repair a hand saw is used for cutting pillars Although hand saws are being used less due to the in crease in the use of airpowered cutting tools in recent years a hand saw is useful when more delicate work is required 2 Chisels Rather than being used for cutting in vehicle repair a chisel is used to remove spot welds on welded panels and for hammering out press lines 3 Cutters Although there are cutters used for cutting metal that have crosscut blades and straight blades today they are hardly ever used tn vehicle repair 5 Dedicated tools These tools are not general purpose tools They are used only in vehicle repair 1 Clip removal tools These come in a variety of shapes There are those like a screwdriver with a flattened Y shape tip 2 Welding clamps These are usually known by product name but are also called vice grips They are used to hold panels to be welded There are various sets with a range of sizes and different shaped heads to suit different repair sites Removal and fitting of parts 8 4 6 How to handle hand tools The basic principle of hand tools is to know what they are used for and not to use them for any other purpose For example you should not use a screwdriver to make a hole in sheetmetal or hit the head of a bolt with a spanner just to speed up the job The lengths
136. re When even more force is loaded plastic deformation becomes greater and the internal structure of the sheetmetal fractures The force at this point is the sheetmetal s tensile strength When force greater than the elastic deformation of sheetmetal is loaded both plastic deformation and elastic deformation occur When the externally loaded force is released parts with elastic deformation return to their initial shape while parts with plastic deformation will not return to their initial shape When a panel is deformed in an accident for example plastic deformation and elastic deformation occur Depending on the state of deformation in many cases there is plastic deformation which constrains the recoverability of the elastic deformation At such times elastic deformation will naturally recover if the part with plastic deformation is repaired 2 Work hardening When sheetmetal undergoes plastic deformation it will become harder and its strength increases This is known as work hardening When body panels are made the steel is work hardened using press forming This is because exterior panels have an extremely thin thickness of 0 6 0 8 mm and the required strength cannot be obtained without this process Work hardening also occurs in panels that have been deformed in an accident Consequently if force to recover its shape is loaded incorrectly all that happens is that other parts will become deformed and the deformed parts will not reco
137. rements The diagonals of the sym metrical quadrangles are the same A vehicle body has many symmetrical parts and this makes it possible to see deviation Use a rod or something similar to measure the length of one of the diagonals and then use it to measure the other diagonal If the lengths are the same the vehicle is normal but if the dimensions are not the same there is deviation However this only tells you the positional relationships of the four corners of the quadrangle and nothing about the panels in the middle Also since the body is three dimensional deviation occurs not only at the right and left of the front and back but it also occurs above and below Determining deviation based only on two dimensional diagonals has its limitations W Compare the opposing corners Repair of the underframe 9 12 3 Numeric conversion To grasp an accurate picture of the state of the vehicle lengths need to be substituted with numbers and inter preted This is the task of measuring Taking measurements will for example tell you that the upper surface of the front fender is 800 mm on the right and 780 mm on the left However this information is not enough You must refer to the body manual to check the original dimensions When you do this you find that the correct length is 805 mm This tells you immediately that both lengths are wrong 2 Types of measuring devices and characteristics The tram gauge and centering gauge are exa
138. repair 5 17 3 Combinations with hammering Pulling alone is not sufficient to restore panels Sometimes using a hammer is faster when roughing out Even at the panel repair stage it can be quicker to hammer the surrounding area while maintaining pulling force as this will remove plastic deformation in the panel and restore elastic deformation When repairing a small deformation it is sometimes simpler to use a hammer and dolly Using appropriate com bination of tools mainly hammers in this way is a way of shortening work time when repairing panels Also the hammers used do not have to be metal iron In some cases mallets and plastic hammers are used to beat lightly in order not to stretch the panel 8 Identifying damage patterns and repair work 1 Identifying damage patterns Panels are deformed in a variety of ways A close comparison shows that no two shapes are the same Though the shapes might be different the basic characteristics of damage are the same Whether the damage covers a wide or narrow area has shallow or deep dents and the number or size of creases does not really have much effect on methods or order of repair work Damage manifests itself in different ways A look at the types of damage while mindful of work order and meth ods in the course of everyday panel repair work reveals there are surprisingly few different types of damage Identifying damage patterns allows individual deformations to be treated as varia
139. rms with standard 6 Wheel alignment tester Measures each of the factors for wheel alignment separately for each of the four wheels It is also known as a four wheel alignment tester It can show differences between actual values and reference values Appendices 3 Appendices 4 7 Dust suction system It sucks up and collects sand and dust generated when sanding body filler from the floor When using a dust suction sander put the tip of the hose into a gap in the mesh panel in the suction inlet in the floor There are other portable cleaners for one sander or several sanders as well as dust collection systems with ducts in the ceiling or wall that collect dust from around 10 sanders 8 Drier Accelerates putty drying Driers have various heat elements including infrared lamps and halogen _ lamps They range in size from hand held dryers to drier banks Appendices 5 2 Related technical resources When working on a model or a repair site for the first time gather information by referring to technical resources on how to proceed with the repair work Related items are as shown below 1 Body repair manual Sites and materials 2009 Plastic parts zinc plated sheetmetal high tension steel BODY REPAIR MANUAL Rustproofing agent treatment sites Sealers rustproofing wax undercoat SUBARU Panel components and cross sectional diagrams of interlocking
140. s However finishing a sheetmetal surface so that it is perfect requires much work and a lot of time The more you hammer or pull out a panel the more the panel will stretch This will disrupt later processes It is possible to use putty to repair dents that are up to 10 15 mm deep There should be no stretching Different putties are used depending on the depth of the dent Stretched areas should be fixed before this stage Basics of applying putty Different putties have varying limits for the depth to which they can be used Ascertain the limit of the thickness of the putty you are using However the thickness stated in the specifications is not achieved with a single applica tion It refers to the allowable final thickness after you have gradually built up the putty A single application will fill a depth of around 10 mm Apply the putty in two steps if the dent is deep Keep the surface filled with putty as clean as possible If there are obvious applicator marks sanding will take time and it will be more difficult to create a smooth surface When the required amount has been applied put the spreader down and gently smooth the surface to get rid of the applicator marks Sheet metal treatment 6 8 Preparation Before applying putty use a duster gun to blow away dust from the repair site and use a cloth containing a de greasing agent to remove dirt and oil If putty is applied on top of dirt sand dust or oil there will be pr
141. s an impact in an accident for example its structure must be such that as much as the impact force as possible is not transmitted to the passengers Bodies designed taking this in account are called impact absorption structures and crash safety bodies Special design features are included in an impact safety body One is disintegration of the part that receives the impact as a means of absorbing the force Of course this does mean that the structure is such that the entire body simply disintegrates Sections that concentrate stress are put in the underframe structure at the front and rear of the body The structure has sharp curves a crinkle pattern and open punch holes These impact zones disintegrate as they were designed to do when the body receives an impact W Structure absorbs energy from the front W Structure absorbs energy from the side Floor cross member Side sill Floor rear cross member Torque box NR ee CR nl ES Ai D i D Fi D LE II eg ee Te LT a i EE te em D E de ee Le et KT H AN e ba ES ees 2 er Floor side member Front side member 2 Floor cross member Floor rear cross member Body construction H 6 5 Structure of body sections 1 Front body Heavy parts integral to vehicle motion such as the engine and transmission are found in the front body They must support the force receiv
142. s and the anchoring system and when it is firmly in place tighten the connecting pipes The setting is now completed For the fastening type that uses chains support the body by placing rigid racks against the right and left connecting pipes Then anchor the vehicle by attaching at least four chains to the front and back on both sides of the vehicle If the vehicle is severely damaged it is a good idea to add chains in the pulling direction and in the opposite direction Attach underbody clamps to the four sites of Lift the rear side using a jack and set the side sill flanges the anchor stand Place the rear side on the anchor stand Once both front and back are on the anchor stand and set the anchor stand in the same way join the connection pipes and fasten the vehicle for the front side using chains wedges and bolts If the hoist is installed at the center of the floor type repair equipment those operations and can be completed at once Repair of the underframe 9 10 2 Setting platform type adjustment and alignment equipment After moving the vehicle near the equipment either tilt or lower the platform and either drive the car onto the platform or use a winch Return the platform to its proper position raise the vehicle on the platform using the jacks that are originally in cluded and attach the underbody clamps and anchor stands Take down the jacks and fix the anchors to the base Setting is now completed For
143. s direction However this would be wrong Even if the front is pulled on a diagonal from the front the force will disperse to the direction of the side member and the radiator support which would not be effective The clamps would most likely come off If the pulling di rection and the panel surface to which the clamps have been attached are not aligned bending moment will act on the clamps and the clamps will come off and the panel to which they were attached will be deformed It is best if the panel surface surface to which the clamps are attached and the pulling direction are all aligned In other words you should pull from virtually face on despite the deformation of the side member that has been pushed back This will make the most effective use of the pulling force In the same way you should pull on the deformed radiator support and cross member from virtually side on while being drawn into the side member For the right side member that is bent slightly upwards force should be applied from straight in front of the front The basic rule is to apply force from these three directions To put it more precisely envisage the damage panel returned to its correct position Decide on an angle which will allow a straight pulling direction This point requires considerable thought Generally speaking vehicle body panels are a combination of vertical and horizontal panels and because there are no panels in a diagonal direc tion always decide to pul
144. sed to clean the surface once work has been completed 6 Metal surface zinc phosphate finishing agent This one component type creates a thin zinc plated layer on the panel sur face It is used for rustproofing when repair work has been completed The agent is diluted with water and brushed on and is washed with water when semi dry 7 Wash primer This is usually a two component type and is a metal surface finishing agent with an added rustproofing pigment It has much better corrosion resistance and adhesion Follow the instructions in the manual as the contents vary slightly depending on the manufacturer External panel repair 5 11 External panel repair 5 12 8 Putty It s difficult to get a perfect panel by just pulling or hammering Putty is used to repair tiny bumps and dents once panel work has been completed Putty is used to attain the final surface because in panel beating the surface is restored so that it is slightly lower than the finished surface It s common for panel beaters to also have to apply and sand back putty Putty is a primer coat used to fill dents The filling depth and fineness of the material are in inverse proportion to each other Panel beaters use either a metal sheet putty or an intermediate type of polyputty Putty is mainly made up of an extender and a polyester resin in order to maintain its bulk It reacts with a hard ening agent and takes a short time to harden The compoundin
145. seseeecseaaeessesaseeessageeeeeas 2 2 Damage analysis EE 3 3 Preparation NEE 3 4 Removal of parts EEN 3 5 Underframe repairs sais eases aciwexaunawe cavdennnccaacanvacseuvacmnsaancscnsavnceaeenraeaancacsesoatanssanaeriaiabidensan sudan iaeenansaaveuneentween 4 6 REDIAGING welded Re Ce E 4 7 Panel beating exterior panels teste gege ege eege EE 4 o PANUNG ME 4 LPN ge EE 4 10 GOMPIETION checks ossis Ea Eaa iOa 5 Repair procedures 4 2 1 Order of tasks Damage caused in an accident varies and damage will always be different even in the same kind of ac cident However there is a standard order in which to make repairs which can be followed for all types of vehicle damage Repair work is broadly divided into panel beating and painting 1 Panel beating Panel beating is the task of using various tools and machines to restore deformed panels the body and members to near original condition It involves re placing panels that cannot be restored or which will require too much time as well as replacing damaged suspension engine and other parts with new ones In the narrow sense of the term panel beating refers to the repair of panels only 2 Painting Painting is the task of painting restored panels and new parts so that they look like new When panel beating has been completed the quality can vary depending on the skills of the worker and methods used but they never really return to their pre damage state Some surfa
146. side sills doors and the middle of fender However since it is easy to remove the front fender you can remove it to panel beat it by hammering External panel repair 5 6 2 Hammering and pulling Pulling has the following advantages over hammer Ing a Because pulling is done from the outside the work can be done regardless of whether the other side is a pouch structure or whether there s an obstacle in the way There is no need to cut the rear side or remove and replace parts more than Is necessary b Hammer blows stretch sheetmetal There is rela tively little stretching when pulling You can also get away with doing a minimum of shrinking c Work is fast because a large amount of force can be applied if necessary d By using a variety of tools and attachments you can acquire the necessary skills in a relatively short period of time 3 Massaging Although hammering and pulling are the two main methods of panel beating there is also massaging Dents are repaired by pushing them out from the rear side of the panel This is used for small dimples like those caused by hail Special kits of dent tools are used for this process A thin long rod like dent tool is put under the dent and the dent is massaged from the rear using the rear panel as a fulcrum This makes it possible to re pair the dent without damaging the top paint Since the tools are inserted into the back of the pan els use the tool with the correct sh
147. so put a glove on it as well so you can t feel the temperature of the panel surface Run the palm of your hand from the probable deformation site outwards Deformation is easier to detect if you draw your hand away rather than drive it in This is because detection is easier if you start low and move higher rather than starting high and moving lower Feeling with fingertips Easy to tell Difficult to tell lt a Check with your non dominant hand 3 Sand using a sander If you use a disc sander or special paint removal sand Sanding mark will er to lightly sand the deformation site the paint will wes R I be left clearly remain in low spots and most of it will come off in 3 raised spots Even after the paint has been removed i S 7 Paint film will be left the size of the sanded area left on the metal section No sanding mark will be left of the panel will make it easy to see which parts are raised and which are low However if you leave deep sanding marks it will take time to fix it up later on Therefore sand as lightly as possible using uniform force across the entire area You can also use a file instead of a sander If you file lightly with medium grained file filings won t adhere to low spots 4 Use chalk Take chalk used to write on the blackboard hold it sideways and run it over the body Normal parts will color up while the color of the chalk won t stick to Chalk SE ere the
148. sorb engine noise and vibration The bolted on hood and front fender have minimal effect on strength However the shape and structure of the hood have changed recently to protect pedestrians when collisions occur W Front body structure and parts 1 Upper radiator member 14 2 Hood lock stay 15 3 Radiator side stays 16 4 Lower radiator panel member 17 5 Lower radiator member 18 6 Front suspension bracket 19 7 Closing plate 20 8 Right fender bracket 21 9 Right front wheel apron 22 10 Upper front wheel apron 23 11 Upper side member 24 12 Battery bracket 25 13 Front tie down 26 Left front wheel apron Left fender bracket Front side front member Front bumper bracket Spacer Front member gusset Front of front member blade Plate A Plate B Hook pipe Front member gusset C Rear front side member Toeboard reinforcement 27 28 29 30 31 32 33 34 35 36 37 Body construction H 7 E High tension steel Front floor cross member Toeboard side cross member Pitching stopper bracket Toeboard center cross member Side member Front panel and duct Front panel Toeboard Gusset Hood Front fender Body construction H 8 2 Center body The center body is the passenger compartment used for passengers and goods The interior space is like an empty box as there are no structures that have to be installed transversely from right to left or top to bottom With doors and win
149. t however it is difficult to accurately determine the amount of force and direction Even if it were possible the momentary force of an accident and the slower task of pull ing are not the same Also body panels damaged as a result of the impact may already have a different strength compared with the original body as a result of work hardening Repair of the underframe 9 17 2 Pulling systems and characteristics 1 Principles of hydraulic systems Hydraulic systems are indispensable when repair W Pascal s principle ing a vehicle body Pascal s principle applies to hydraulics Namely if there is a piston with a sectional area of 10 cm and 1 kgf 9 81 N of force is applied to oil fluid inside a device a separate piston with a sectional area of 100 cm connected by the same fluid will move with a force of 10 kgf 98 1b N If the size ratio of the piston SZ if 1 kg f 9 81 N of force is applied using a piston with the on the input side and the piston on the output side sectional area of 10 cm since the force will be applied equally to the whole liquid the piston with the sectional area of 10 times bigger 100 cm will have the force of 1kg f x 10 In other words the ratio between the force and sectional area is always the same is altered the same force can be increased infinitely However the strokes will decrease correspondingly 2 Hydraulic mechanism In a simple hydraulic device used in body repai
150. tached using adhesive is attached by either direct bonding or flash E Flash mount method Body flange mounts The glass is attached to the body using adhesive for both methods and in direct bonding the mole is attached using clips and in flash mounting the mole is buried in the adhesive The adhesive method gives a vehicle more rigidity compared with the weather stripping method but makes attachment removal and replacement more difficult Ceramic coat Weather stripping This is also known as the gasket method The glass is fixed in place using H E Weather stripping shaped weather stripping and a non drying sealant is filled in the space between method Body flange the glass and body Mole y Adhesive Weather stripping Removal and fitting of parts 8 7 2 Removal and fitting Removal For windshields attached using adhesive remove using either a E Removing with a knife glass knife or piano wire Hold the knife with the blade and glass at a right angle and cut out the adhesive sliding the blade along the glass Start where the gap between the glass and body is the biggest and be sure not to twist the knife Locating pins are attached to the corners of the glass so remove these using piano wire When using piano wire make a hole in the adhesive using a drill or cutter put the piano wire through and attach both ends to a A A 2 short piece of wood Pull on both ends of the piano wire and cut away
151. tal cccsecccsesecseeescneeeeneeeecessccnenececocnesecnsesensesonseeeeseeccnesscessecnssecnsescnsesenesesosesecness 20 RVC ANS OS FSCS CTL Sh EE 20 2 Detecting and preventing stretching EE 20 3 Principles of SHrInKINO WEE 22 A ordir e EE 23 External panel repair 5 2 1 Scope of deformation 1 Types of deformation Body panels deform when they receive an impact Dents are caused but they are not the only sites where de formation occurs There are cases where deformation occurs at sites away from the point of impact entry This depends on the direction of the impact site and degree of force This type of deformation is called indirect deformation or secondary deformation Deformation caused at sites that received direct impact is called direct deformation or primary deformation It is common for indirect elastic deformation caused as a result of an impact to occur at sites that are fixed to the damaged point of impact Consequently this deformation will naturally return to its original shape when the main deformation is restored Inadvertently restoring the damage starting with the indirect deformation will make restoration more difficult as it could require stretching panels To do the work efficiently in a short period of time it is important to follow the correct order based on an accurate assessment of the type and state of the damage Mi Types of deformation Direct deformation Indirect deformation Elas
152. th and safety measures 1 9 4 Maintaining a tidy workshop A tidy workshop is the first rule of safety All equipment tools and materials should be stored in a pre determined place and returned to their original places after use Leaving machine tools and materials on the workshop floor is very dangerous as you can easily trip over them Arrange the items you will need in a tool cart beforehand place the cart near the vehicle you are working on and take the items from the cart and put them back while working This prevents machine tools from cluttering up the floor It also makes for more efficient work W Being tidy prevents dangerous situations Maintaining a workshop tidy 2 It s easy to trip over tools left lying on the floor Health and safety measures 1 10 Body construction H 1 Chapter 2 Body construction Contents 1 Passenger Vehicle TE 2 ah tee TE ope INE oea EE E E A EE E E AEE E EES 2 PTRO d TE 2 EE EE 2 4 eA e 2 2 Characteristics of the unitized body cccccceeeeceeeeeeeeeeeeeeeeeeeeeeaneeaeeseeeeseeeaeeneeeeaeeeeaneeaeesageeesneeaeeneesaees 3 3 Rigid and truss structures E 4 4 Characteristics of the crash safety body cccccsccceecceeeeseeeeeeeeaneeaeesaeeeeeeseaneeaesaeeeeaneeaeesaeeseeneeaeesaeesaeees 5 5 Struct re of e E EE 6 T FROME ee EE 6 CEE e e LEE 8 GER gl e LE 10 Body construction 2 2 1 Passenger Vehicle Frames A monocoque body structure is a
153. that Waste heat tube contains a porous material and is dissolved in other Burner tip Oxygen valve Acetylene chemicals Pressure is 15 5 kg cm2 An acetylene cylinder is for preheating hose plug Cutting torch Acetvlene valve brown Oxygen valve Acetylene valve Q Oxygen regulator Lowers and maintains the pressure of the oxygen as it leaves the cylinder Acetylene regulator Lowers and maintains the pressure of the oxygen as it yereing torch leaves the cylinder One touch hose connection The hose used for oxygen is also black and the acetylene hose is also brown Torch The amounts of oxygen and acetylene can be adjusted separately There are torches used for cutting and torches used for welding Handling of welding equipment 12 Replacement of welded panels 11 1 Chapter 11 Replacement of welded panels Contents 1 Replacing welded panels cccccccccecceeeceeeeeeeeeeceneeaneaeeseeecaneeeeseeecaneeaeseeesaaseaasaeessassaasanesenessaseneseneseeeseesons 2 Oi PRS un Lee Ee TT E 2 SE e TED AC ONO EE 2 2 Order for replacing Welded panels cccsccccseecceeecceseccceeeeceeeccasenceseeeaneneeseseageseasseeesessaseseaneseaneseaneseaeesees 4 1 Removing damaged parts eme 4 2 Preparation Tor MING EE 5 F e E 6 ne TE Me TEE 9 KEREN 9 BH ae Tee fa E e 9 Replacement of welded panels 11 2 1 Replacing welded panels Welded panels can be replaced by either using
154. that box areas in panels will have stretched For this reason a method that applies uniform force over a wide area should be adopted to prevent more stretching One effective method is to arrange a row of washers and pull out the panel 3 Narrow sharp angled deformation 1 Characteristics Stretching has already occurred in narrow sharp angled deformation in high crowns corners and highly rigid panel surfaces and there is a risk that more stretching will occur during repairs Even if you attempt to pull out the center of the deformation the deformation can easily bring the surrounding area up with it 2 Repair work Keep lifting in check by beating the surrounding area while pulling out the deformation First pull with strong force and lightly beat the area that has lifted while maintaining that force Be careful not to beat too hard as this will cause the panel to stretch Restore it slowly making sure not to reverse the panel s elasticity This is done faster by applying force from the edge not the center of the deformation GN Deep dents Shallow dents After roughing out with a dolly and slide hammer repair by hammering Either use a dolly from behind or pull out by attaching a washer and starting with off dolly and then changing to on dolly hammering For pan hammer the surrounding area while retaining that force When the defor els that have been pulled hammer while maintaining the pulling force mation is reduced change
155. the repaired 3 Roughing out In cases of severe damage return the press line or panel shape to as near as the original shape as possible 4 Remove paint film Limit the removal of paint film to as small an area as possible required for attaching a washer etc 5 Attach an earth To attach a washer attach a minus electrode on the same panel as near as possible to the repair site or somewhere where it will not get in the way First remove the paint from the spot where the earth will be attached 6 Repairing panels Repair the damage using various panel pulling tools 7 Fixing holes made in the body When the repair has been made if there are small holes left by washers etc place MIG welder wire around 0 6 mm up against the hole and weld it on from above passing the current through the stud If once does not fill up the hole do it a second time 8 Checking the damage Check whether the damaged panel has been finished to a level where body filling can be done Also check to see whether or not the sheetmetal has stretched 9 Shrinking If the sheetmetal has stretched shrink as necessary 10 Sanding the surface Sand off traces of the washer on the panel surface Also check for small marks 11 Surface finishing Rustproof metal surfaces using a zinc phosphate finishing agent or washer primer 12 Applying putty Apply metal sheet putty or polyputty and sand when dry so that the surface is back like it was before the damage External panel
156. tic deformation 2 Washing and cleaning It is vital to wash the vehicle before starting work Wash the entire body Pay particular attention to the damaged site and surrounding area It is hard to see the damaged site or determine the state of the damage if there is dirt or mud on the vehicle For this reason clean the car by washing not only the body surface but also the other side of the panels with water and remove any grease using a detergent Wash the car starting at the top and work down 3 Checking for dents and bumps 1 Visual check If the paint film is not damaged make a visual check for any deformations by shining a light on the body surface They re easy to see if you leave some space between you and the site you re checking If there is not much light wetting the site with water is useful Sometimes they re easier to see if you change your po sition or angle and make a comparison If right and left have the same shape use the non damaged side for reference External panel repair 5 3 2 Hand check When the deformation is tiny or you re nearing the finishing stage it can be extremely difficult to tell what has been restored to its original shape and what hasn t With experience you will be able to perceive tiny dents by running the palm of your hand or fingers over an area Standard practice is to do this with your non dominant hand and to wear a thick cotton glove The skin on your dominant is thicker Al
157. tion to the side frame for example is small compared with the overall damage check to see whether the side frame has gone into the toeboard 3 Arrangement of opening parts and body damage You can tell deformation from the gaps H Distortions between the gaps of the panels and the body between the doors hood and adjacent panels If the gap on the front side of the Small gap Correct gap front door is narrower even if the gap on Damage up to the other side is normal it means that the front pillar the damage didn t go further than the front pillar If the gap at the rear side is also narrower it is highly likely that de formation has occurred in the roof and side sills Damage beyond If you look at the gap between the front the front pillar fender and the hood you can detect de flection in the front body For example if the right of the front end is narrow and the left is wide it means that the body is Fender is bent toward the right If the right of the Small l high gap Fender is low hood is high and the left is low it means the right side has been raised S Large Hood 2 gap Front is bent towards left Right side has been raised at the front Damage analysis 7 5 4 Front end collision and damage Damage to the front of vehicles is the most common When impact is light it first pushes the bumper and deforms the front side member via the bumper stay Depend ing on the impact site
158. tions of those patterns which makes it easy to draw up a work plan It also shortens work time 2 Wide mild deformation 1 Characteristics Wide mild deformation occurs ZE easily when a not very strong Rather than applying strong force repair with gentle force force is applied to panels with near flat wide surfaces It is mostly elastic deformation CO though partial plastic defor mation prohibits the restoring Partial plastic deformation Deformation taking the form of a step Once the plastic deformation is Rough out by applying force over wider area force of the panel Plastic de repaired the entire section will and starting with off dolly and then changing be restored to on dolly hammering formation is easily identified as sharp angled deformation d and peeled paint occur only in those areas Sr External panel repair 5 18 2 Repair work Restoration is relatively easy because sheetmetal does not stretch very much Basically if those areas with plastic deformation are repaired the other areas will naturally regain their original shape However if a dent is formed again when pressing lightly on the restored part it means that the sheetmetal has stretched at the part where there was plastic deformation Shrinking then becomes necessary At the end of panels and at sites where there are reinforcements the deformation takes the form of a step When the impact entry point is nearby it is possible
159. tly and sand applying the entire surface of the pad When finished rustproof the surface by applying a metal surfacing agent or a primer Sanding the surface of rustproofed sheetmetal will remove the zinc plated layer so this has to be done again Sheet metal treatment 6 7 3 Applying putty Handling putty Stir the putty before using Use a special stirring stick so that impurities WW Stirring putty don t get mixed into the primary agent For the hardening agent in a Stir the putty sufficiently before using tube push down hard and mix it in with the cap firmly on Make sure you put the lid on the primary agent can so that dust and oth er impurities don t get inside Commonly omitted from instructions on the container is that there are putties for different temperatures stan dard summer and winter Once you have opened the can use it up as soon as possible When it is cold you can dip the can in 60 C hot water to soften it Do not use an infrared drier The primary agent to hardening agent is based on weight so measure accurately using scales If you have a good feel for the correct quantity itis also okay to measure the quantities yourself Timing for applying putty When repairing panels with tools the extent to which a precise surface is achieved depends on the workshop s quality policy and the skills of repairers Applying putty when as clean surface as possible has been made will shorten later processe
160. to on dolly W Width of a dent and how to apply pressure Wide dents Pull out the whole dent using a slide hammer 4 Long narrow deformation 1 Characteristics It is common for long deformation to be elastic deformation and for short to be plastic deformation Accordingly don t apply much force to lengthy deformation don t beat much with a hammer and repair the damage in the short direction 2 Repair work Pulling requires a relatively large amount of force Since working from the center of the deformation will stretch the sheetmetal if the deformation is long repair it little by little from both edges moving toward the center along the longitudinal direction of the panel Conversely if the deformation is short working on parts will stretch the sheetmetal Applying large force to the center of the damage in short bursts will be quicker in some cases 5 Creases 1 Characteristics Narrow dents External panel repair 5 19 Pull using the reverse movement of the weight Rough out first by pulling with stronger force and repair by hammering while maintaining the pulling force Soldered thin plates or connected washers Force is maintained Large slide hammers chain pullers etc This kind of deformation occurs when force is applied in a lengthwise direction to the panel surface Although if the damage is severe the panel should be replaced restoring this damage is not as difficult as it
161. to the rear door will be bent An impact absorption structure is mainly used on the corner of the rear side members In front wheel drive vehicles particularly those with a rear gate the simple body structure around the back end means that there will be greater deformation for the amount of impact force In some cases deformation will extend to the center area and the center pillars 7 Damage caused by secondary impact E in th n f di f M men ven in the absence of direct force movement E Damages caused by luggage and other by the passengers luggage engine etc caused Windshield e SS S Steerin by an impact can cause damage This is called ig secondary damage For example the movement EE dir EN Trunk room of luggage in the trunk can cause damage l The radiator engine and transmission mounts and base of the gearshift can be deformed by engine movement If impact is major the inertia force of the vehicle may cause damage to com Ka paratively hard parts This occurs in the roof and side sills Damage analysis 7 6 3 Damage to outer panels Because damage to outer panels appears in the form of dents buckles scratched paint film etc it can be diag nosed by a visual check and by feeling with the hand There are two types of damage to outer panels There is plastic deformation where they have received direct im pact and there is elastic deformation which occurs indirectly in the surrounding area
162. urement KB Sk a a RA e ONA 2 Underframe construction and damage 1 Damage prone places Because body strength varies depending on the area and impact absorption construction is used in some places each part of a vehicle has tp S spots that are prone to damage If you check Sections where panels jp these spots you will get an idea of how far the Have een JOINS g force of the accident has traveled Damage prone areas are areas where stress Change in shapes a sche concentrates They include around punch holes corners places where the thickness of a mem ber or reinforcement changes and where pan els have been joined Creases Corner section Change in shapes Surrounding area of the holes and space Damage analvasl 7 4 2 Easily overlooked damage Huge bends and dents are easily seen However if there is not much deformation it can sometimes be difficult to spot it with a visual check For this reason it s only natural that you check by taking measurements There are some points to look out for when making a visual check For example when a frame member is bent it can be hard to tell from the outer side of the direction of the bend In such cases if you check the inner side too you will be able to tell from the creases Conversely even if something does not look to be bent if there are creases on the surface it will be bent and the side with the creas ing is the inner side If deforma
163. urement Repeating measurement and repair Final measurement Replacing welded parts Remove fastenings 4 point anchoring Procedure of the repair equipment to be used Safety measures Utilizing measurement devices included in the repair equipment and various measuring devices Adjusting the positions angles and forces of pulling and pushing Utilizing various clamps Safety measures Dimensional drawing of the body Utilizing measuring devices Utilizing measurement devices included in the repair equipment and various measuring devices Utilizing the body manual Optimal use of various welding equipment and tools Safety measures Procedures of using repair equipment Safety measures Repair of the underframe 9 3 2 Body adjustment and alignment equipment 1 Development history Repairing a vehicle body deformed in an accident most likely started at the same time as the invention of the automobile In those days repairers inherited repair techniques used for horse pulled carriages For a long time basic body construction remained virtually the same as that used for carriages except that wood had been re placed by iron Huge changes appeared in body construction with the birth of the unitized body There was a significant increase in vehicles with the unitized body in Europe after the Second World War That was when special repair tools for this type of body and present day body adjustment and
164. urrent Arc discharge starts removing the paint film making a hole in the up fawn the welded Baam per panel and then filling up the hole A seam part is cut with magnetic force weld is where a 1 2 mm gap between panels a Magnetic force is filled in S If there is a site where it is difficult use these methods make a fillet weld on the end of two overlapping panels 2 Components A MIG welder consists of the weld torch which Regulator Main unit feeds the wire and shield gas an earth clamp a os a Wire supply mechanical unit with a built in wire drum some ebe ore section welders have an external wire drum and a gas cylinder positioned to the side Carbon dioxide gas cylinder Handling of welding equipment 7 3 Main unit Voltage current and the timer are controlled within the main unit By calibrating the control panel the welder will set the appropriate values 4 Wire feed unit This unit consists of a wire reel and a wire feeder The wire reel is housed either in the main unit or in a separate unit The wire comes in a variety of diameters and materials Wire diameters include 0 6 mm and 0 8 mm and if the workpiece is an aluminum alloy panel aluminum wire should be used Check the wire feed unit daily and remove dust and oil 5 Torch When the switch is pressed it feeds the wire through which the elec tric current passes as well as gas through the nozzle Since it is used
165. us if it comes off 3 How to use a dolly Hold the dolly so all of it fits in the palm of your hand Don t grip it but hold it gently As with hammers the surface of the dolly should always be clean Remove dirt etc when it appears 2 On dolly and off dolly There are two methods of repairing using a hammer and dolly They are hammer on dolly on dolly hammering and hammer off dolly off dolly hammering Use a combination of the two methods 1 On dolly On dolly is when the panel is between the dolly and hammer The dolly absorbs the striking force of the hammer and the panel retracts a little from the dolly By placing it up against the panel again it is struck from behind so the panel becomes flat with force from both sides 2 Off dolly Off dolly is when the hammer and dolly are not aligned at the panel Sometimes it is when the dolly strikes the panel from behind The further the distance between them the weaker the effect of the beating When repairing a panel start with off dolly and finish with on dolly Take a careful look at the damage envision what the fin ished product will look like and hammer methodically until you arrive at something like the finished look Continuing beating just the dent with force won t restore the shape There should be no scratches or dirt It should be flat or the central part should be slightly lower This angle should not be sharp M How to place an dolly fm
166. val J 7 Plane grinding of Sanding the old pain Paint film the metal sheet putty paint film Polishing removal Differs according to colors or paint to be used W Structure of sandpaper Open Closed coat coat Sanding particles Backing Sheet metal treatment 6 6 2 Surface preparation procedure 1 Removing paint film Paint film is removed when pulling panels in order to earth a tool or to attach a washer When the repair has been made remove paint film from other damaged areas for surface preparation Use a disc sander for this task Use sand paper with a grit size of P60 to P80 Place the disc sander lightly against the painted surface hold it at a 15 20 angle and sand evenly If you push too hard against the surface the heat of friction will cause the sheetmetal to deform When repairing a small mark it is okay to use a double action sander and start with a grit size of P120 Since sanding will produce dust wear a dust mask and safety glasses 2 Feather edging Feather edging is tapering the edge where the metal surface that ap peared by removing the paint film and the paint film meet Use a double action sander and P80 to 120 sandpaper Use a hard pad Surface preparation is an extremely important car repair process If the job is not done properly sandpaper grains leftover putty and blisters will cause paint defects When feather edging taper off over a wide area Hold the dual action sander gen
167. vehicles with damaged tires that can t be driven use a special support with wheels Place the damaged car on the tilted Set the fastening clamps and Remove the wheels platform by either driving the car or fasten the car on the platform using a winch 3 Setting bench type adjustment and alignment equipment The methods of setting up a bench type system vary depending on whether there is a hoist and on the type of hoist If there is no hoist place the damaged vehicle on a support stand After attaching the underbody clamps put the bench underneath the vehicle raise the bench with a garage jack and attach the anchor stands to the bench Raise the bench higher and take down the vehicle stand If there is a forklift or similar type of hoist that can raise the vehicle from the side a stand is not needed as the vehicle can be placed directly on the bench Raising the vehicle with a hoist with four or three columns makes this task easy Since the bench has casters after setting up you can move it to a space where you can work on the vehicle If the bench body is attached to a hoist raise the vehicle once on the bench support the vehicle with a special stand and then attach the underbody clamps Although you can t move it once it has been set up the vehicle can be raised and lowered while working Benches that serve as measuring systems can also be used in conjunction with floor type and platform type equipment In such cases the vehicle is an
168. ver their initial shape If heat above a certain temperature is applied to a work hardened area the hardness created through the process will be eliminated and the area will return to its original elasticity This is known as annealing If areas that have work hardened and have become difficult to repair are heated with a torch they will become soft and will be easy to return to their original shape However the heat fractures the metal s internal structure which will mean that the sheetmetal used in the body has considerably lower strength Accordingly as a basic rule members in underframe areas that ensure the body s strength and other welded panels must be repaired using annealing Body materials 3 9 Elastic deformation en a zm ze rm mm mm nnmn ell Plastic deformation r i L DU H l I l I l L e ps mm ms mm mm mm mm Ten mn mm w y Work hardening Effect Before pressing After pressing ee S eg reg gg Even for a thin plate that easily undulate when applying force while it is left flat if the press line is added the line section will be work hardened and will have the same effect as inserting reinforcing members Body materials 3 10 3 Work hardening of panels Work hardening is used to increase the strength of panels There are the following types of press lines that bend panels 1 Flange A flange is an edge that projects at a right angle from a
169. weigh approximately half as much for body panels as sheetmetal have the same strength O e owon Cows OOOO yO See ER Body materials 3 3 2 Properties of metal 1 Common properties Iron and aluminum used to form shapes are called metals Metals have the following common characteristics They e Shine when polished metallic gloss e Are solid at room temperature mercury is an exception e Have acrystalline structure when solid e Are opaque Are very hard Have high tensile strength Have plasticity Are forgeable e Are resistant to fatigue e Have a positive atomic value on their own they have positive ions e Have good heat conductivity Specific gravity Metals have a high specific gravity Melting point Although they are solid at room temperature excepting mercury they expand and melt when heated They turn into liquids Melting point is the temperature at which this occurs Thermal conductivity They conduct heat easily Conduction They conduct electricity easily Silver gt Steel gt Gold a Electrical Thermal conductivity Chemical e l Melting point conduction Metal Specific gravity 0 C symbol ac paris ZP Cu 100 ena La O BEER ee ee ew E a wei SC EC Values differ slightly depending on the source Body materials 3 4 2 Mechanical properties When metals are used for body materials their mechanical properties are checked 1 Strength and hardness Strong metals
170. will be transmitted throughout the entire material If the force exceeds the strength of the ma terial it will deform or break but where that will happen can t be known until it occurs However if the area or shape of a material varies for example it suddenly narrows or there is a site where it folds over it will always deform or break at those points This is because the force is concentrated in these areas This is called the con centration of stress Mi Concentration of force The area where the force is concentrated When the whole area is even lf there is an area where the force Punched Change in Curve it depends on the way of applying is concentrated it is always bent hole sectional area corner force for where to be bent from this section 5 Moment of force Objects have a center of gravity which we can think of as the place where that object s weight concentrates This isn t always the place that appears to be its center Force applied to the center of gravity can be seen as applying force to the entire object If the object is not an chored it will move in the same direction as the applied force However if force is applied to a site away from its center of gravity the force will act as a rotational force centering on the center of gravity This is moment The anchored parts of an anchored object will behave like that object s center of gravity When force is applied to an anchored body force will be applied to unex
171. ystems and allow the easy anchoring of single sections They don t take up much space as when not use the various parts can be stored away However the rails or anchors remain in the floor Rails are made of aluminum as well as steel and some systems use a rubber cover to obtain a flat surface The individual parts can be used flexibly in combination with other adjustment and alignment systems and equipment repeat pulling measurement and carry out the final check Repair of the underframe 9 5 3 Bench type systems These systems are based on taking measurements using a jig A jig is mainly used to show the correct positions of major points on the underbody There are dedicated systems that require special attachments for each vehicle model and there are universal systems that can be used for any model by relying on a frame chart Many of these systems are European The platform used to set the jig is a jig bench and pulling systems and setting systems are also set using the bench The bench itself is portable However for reasons of convenience the system is often used in combination with a hoist which means it occupies its own space Lifts improve efficiency as the height of the vehicle can be freely adjusted during the repair process Since all that is required is to pull in the direction of the dimensions and positions showed three dimensionally by the jig work is fast and even the inexperienced can use this system How

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