Teacher`s Guide - Films On Demand - Films for the Humanities and
Contents
1. 2572 Brunswick Pike Lawrenceville NJ 08648 www shopware usa com Call Toll Free 800 487 3392 327852. a Evaluate the existing finish b Apply a wax remover c Apply a wax remover and a degreaser d Prepare a plan for refinishing A c Feedback After washing a vehicle apply a wax remover and degreaser Spray the degreaser on all surfaces to be refinished and wipe it off Paint will not adhere to a surface with wax sil icones or grease 10 0 Paint tends to cover existing blemishes True or False A False Feedback Painting magnifies existing blemishes Blemishes that are not corrected prior to painting may require you to redo the job later In repaired areas check to make sure the sur face is completely smooth and blemish free Check for waviness pinholes sanding scratch es or any other imperfections Q What measurement should paint build up be limited to and why A Paint build up should be limited to 12 mils If it becomes thicker than this the paint has a tendency to crack Feedback Typically the factory finish plus one additional refinish will be slightly under 12 mils or 12 thousandths of an inch Q What is the erosion of the original finish called a Cracking b Cratering c Blistering d None of the above A b Feedback The erosion of the original finish is called cratering Q Where can you find the manufacturer s paint codes and the type of finish used on a vehicle a In the owner s manual b Under the hood c On the door d On the vehicle s identification plate A d Feedback
3. restorations html Automotive Body Repair News www abrn com abrn see www abrn com abrn article articleDetail jsp id 39 995 Automotive Learning Online www innerauto com Auto Glossary www autoglossary com Automotive Plastics Council http www plastics car com s_plasticscar Automotive Services Association www asashop org Automotive Youth Educational Systems AYES www ayes org index asp Collision Repair Industry Insight http www collision insight com Do It Yourself Network Automotive Repair www diynet com diy ab_auto_body_work 0 2020 DIY_13675 00 html How Stuff Works Auto Stuff Page http auto howstuffworks com car www i Car com National Automotive Service Task Force www nastf org 13 National Automotive Technicians Education Foundation Program Standards www natef org program_standards collision index cfm OEM Listing Auto Body Online www autobodyonline com industry OEM index cfm Society of Collision Repair Specialists www scrs com codeofethics htm Tektips Auto Body Pro Website www autobodypro com tektips htm BOOKS Chilton Book Company Chilton s Auto Repair Manual 1998 2002 Chilton Book Co 2003 ISBN 0801993628 Duffy James E CAR Professional Automotive Collision Repair Delmar Thomson Learning 2001 ISBN 0766813991 Duffy James E Auto Body Repair Technology 4th Edition Thomson Delmar Learning 2003 ISBN 0766862747 OTHER PRODUCTS Auto Body Shop Safety
4. AUTO BODY REPAIR TEACHER S GUIDE SHOPWARE INTRODUCTION This Teacher s Guide provides information to help you get the most out of Surface Preparation and Refinishing The contents in this guide will enable you to prepare your stu dents before using the program and present follow up activities to reinforce the program s key learning points A glimmering coat of paint is the finishing touch to an auto body repair job This video takes viewers through the entire process of preparing sanding priming sealing topcoating clearcoating quality checking and final detailing Use the Surface Preparation and Refinishing video and accompanying activities provided in this guide to prepare students for the most effective way to approach auto body repairs and to familiarize students with termi nology used in the auto repair industry LEARNING OBJECTIVES After viewing the program students will be able to E Demonstrate a basic knowledge of surfacing and refinishing operations and safety proce dures Identify the correct tools to use given the task to be performed Identify proper equipment and materials in refinishing Identify specialized finishes Describe procedures for sanding and grit selection E List procedures for masking E Determine proper procedures for spray painting E Explain different types of paints and undercoatings and the procedures for application E List automotive detailing procedures
5. EDUCATIONAL STANDARDS The primary certifying body for automotive technician training programs is the National Institute for Automotive Service Excellence ASE ASE is a non profit organization estab lished in 1972 by the automotive industry to improve the quality of vehicle repair and service through the voluntary testing and certification of automotive repair technicians The National Automotive Technicians Education Foundation NATEF is a separate non profit foundation within ASE The mission of NATEF is to improve the quality of automotive technician training programs nationwide through voluntary certification The State Departments of Education in all 50 states support ASE NATEF certification of automotive programs National Standards This program correlates with the Program Certification Standards for Automobile Technician Training Programs from the National Institute for Automotive Service Excellence ASE and the National Automotive Technicians Education Foundation NATEF The content has been aligned with the following educational standards which reflect the tasks in the ASE Program 2 Certification Standards for Automobile General Service Technician Programs Copyright 2005 SHOPWARE Preparation E Comply with personal and environmental safety practices associated with clothing respira tory protection eye protection hand tools power equipment proper ventilation and the handling storage and disposal of chemicals materi
6. English Language Arts by the International Reading Association and the National Council of Teachers of English Copyright 1996 by the International Reading Association and the National Council of Teachers of English Reprinted with permission Technology Standards The activities in this Teacher s Guide were created in compliance with the following National Education Technology Standards from the National Education Technology Standards Project The content has been aligned with the following educational standards and benchmarks Use a variety of media and formats to communicate information and ideas effectively to multiple audiences Use telecommunications to collaborate publish and interact with peers experts and other audiences Use productivity tools to collaborate in constructing technology enhanced models prepare publications and produce other creative works Use technology tools to enhance learning increase productivity and promote creativity Use technology to locate evaluate and collect information from a variety of sources The National Education Technology Standards reprinted with permission from the International Society for Technology Education PROGRAM OVERVIEW The finish on any autobody repair is the final touch and is a beautiful thing when done cor rectly However when it is applied incorrectly it can mean a lot of extra work So what do you need to know to ensure that the finish turns out p
7. Software Cambridge Educational Safety procedures relevant to the auto body shop are outlined along with lessons on First Aid Fire Safety and Prevention Wire Feed MIG Welding and Proper Use of Auto Body Tools 3 5 IBM version Mac version also available A Shopware Production Order 20941 www cambridgeeducational com 1 800 468 4227 Multimedia Auto Shop Safety Software Cambridge Educational This multimedia CD ROM uses video animation and still photos to examine the topics of general shop safety fire safety and prevention first aid and safe tool use for mechanics The segment dealing with overall shop safety emphasizes the link between cleanliness and organ ization as well as personal safety considerations of glasses earplugs shoes and clothes The first aid portion suggests that a certified first aid class be taken but it offers an excellent survey of first aid practices including what NOT to do Correct fire extinguisher usage is illus trated by memorable graphics The auto workshop is portrayed as a work site of numerous potential hazards while at the same time the viewer is taught how to cope with the chal lenges of volatile auto products damaged electrical cords and welding cylinders and their contents The mechanic s tools are shown to be a statement of their owner s professionalism It seeks to foster that professionalism by describing the safe care and use of hand and power tools wrenches auto body tools and measu
8. The vehicle s identification plate contains the manufacturer s paint codes as well as the type of finish The ID plate is located in different places for different makes and models of vehicles If you are unsure where to find the ID plate consult a crash book Q Paint needs to be thinned to decrease its A viscosity thickness Feedback If paint is too thick or viscous it wont flow or atomize properly If it s too thin it won t cover and will tend to create drips Q is best used to take off large amounts or multiple layers of paint a Blasting b Chemical stripper c Sanding d None of the above A b Feedback Chemical stripper is best used to take off large amounts or multiple layers of paint However it can get trapped under trim and ooze out later to ruin the final finish Therefore use a chemical stripper only when other means are not feasible 11 Q What do self etching primers do A Self etching primers promote paint adhesion and provide corrosion protection in one appli cation Feedback Any bare metal must be treated with a self etching primer Simply spray on the primer and let it dry Q What does primer surfacer primer do A Primer surfacer or surfacer fills in scratches left by sanding and grinding and other little imperfections in the body filler Feedback Primer surfacer or surfacer also provides a good base for the adhesion of the finish coats that follow Q What do
9. als in accordance with local state and federal safety and environmental regulations Safety Precautions Select and use the proper personal safety equipment for surface preparation spray gun and related equipment operation paint mixing matching and application paint defects and detailing gloves suits hoods eye and ear protection etc Surface Preparation Inspect remove store and replace exterior trim and molding E Soap and water wash entire vehicle use appropriate cleaner to remove contaminants Inspect and identify substrate type of finish and surface condition develop a plan for refin ishing using a total product system E Remove paint finish E Dry or wet sand areas to be refinished Featheredge broken areas to be refinished Apply suitable metal treatment or primer Mask trim and protect other areas that will not be refinished E Mix primer primer surfacer or primer sealer Apply primer onto surface of repaired area Apply two component finishing filler to minor surface imperfections Dry or wet sand area to which primer surfacer has been applied Dry sand area to which two component finishing filler has been applied Remove dust from area to be refinished including cracks or moldings of adjacent areas Clean area to be refinished using a final cleaning solution Remove with a tack rag any dust or lint particles from the area to be refinished E Apply
10. ccessful feath eredging if you run your hand over the area where the two surfaces meet it will feel per fectly smooth with no indication where one surface ends and the other begins E When you re planning a spot repair especially with a multistage finish any trim that can be removed should be Multiple finish coats around trim pieces build up a considerable edge which is more likely to crack or chip later If the piece cannot be easily removed then mask E There are several types of masking masking paper and masking tape plastic sheeting and masking tape specially shaped masking covers and liquid masking material Be sure wher ever you mask to cover the part completely but don t overlap onto areas that are supposed to be finished You can remove paint from surfaces that were not supposed to be finished but you cannot successfully add paint to areas that were unintentionally masked off There are four major considerations when applying the final finish a clean environment temperature and humidity light and ventilation A properly maintained paint booth provides control over all of these variables E Paint spray guns combine the paint with compressed air When you pull the trigger the paint is atomized as it comes out of the nozzle meaning the paint is formed into a cloud of tiny uniform droplets When applied to a vehicle these droplets flow together to form a continuous film on the surface E Before the color coat a
11. color match before refinishing the vehicle Paint needs to be thinned to decrease its viscosity or thickness If paint is too thick or vis cous it won t flow or atomize properly If it s too thin it wont cover and will tend to create drips E Blasting with abrasives will quickly remove loose paint and reveal any underlying rust Abrasives that can be used include sand plastic beads soda even walnut shells Blasting with sand may damage thinner steel panels aluminum or plastic Using soda walnut shells or plastic media instead of sand makes blasting safe for all surfaces Sandpaper comes in various grits and in dry or wet varieties The smaller the number the coarser the grit Generally you should select the finest grit paper that will do the job If you use coarser paper it may work faster but you will have to sand out deeper scratches Scratches that are not sanded out will show up in the final finish Primer surfacer or surfacer fills in scratches left by sanding and grinding and other little imperfections in the body filler It also provides a good base for the adhesion of the finish 6 coats that follow Every area that is to be painted must be sanded or scuffed to improve adhesion of the new finish Usually this is accomplished by wet sanding using a very fine 600 grit water proof paper either by hand or with a power sander Featheredging means gradually tapering one finish into the other With su
12. considerations when applying the final finish safety proce dures for spraying finishes how to test and adjust spray guns and how to correctly apply sealer color and clear coats Topic 4 Detailing This section of the program discusses the imperfections to look for after a new finish is applied how to correct those imperfections and what procedures should be followed to thoroughly clean and prepare the vehicle for delivery back to its owner FAST FACTS When preparing a vehicle for refinishing it is important to apply a wax remover and degreaser Paint will not adhere to a surface with wax silicones or grease One thing to check before refinishing is how much paint buildup exists on the vehicle Typically the factory finish plus one additional refinish will be slightly under 12 mils or 12 thousandths of an inch Paint build up should be limited to 12 mils If it becomes thicker than 12 mils the paint has a tendency to crack Before refinishing you need to find out what kind of finish the car has and match the color and the type of paint The vehicle s identification plate contains the manufacturer s paint codes as well as the type of finish The ID plate is located in different places for different makes and models of vehicles E Paint colors vary slightly from batch to batch even with precise measuring and mixing Over time a vehicle s finish can fade Therefore it is important to create a test panel to check the
13. control the four major considerations Also describe other features you would like your paint booth to have What would make your paint booth different from or better than the ones that exist today You d Better Shop Around A happy customer is always the best customer As a group create an Auto Body Paint Shop guide for customers that describes some of the things they should look for in an auto body shop so that they can get the best refinishing job Include tips on how to select the right shops what types brands qualities of paints are used and how each type of paint is dif ferent how much time it takes to repaint a car and how to save money INDIVIDUAL STUDENT PROJECTS Refinish Me Safely Prepare a brochure booklet or poster that illustrates at least five important safety precau tions that you should take when refinishing a surface Include a description and an illustration of the dangers that each safety precaution help to prevent and describe the consequences that could result from not taking these precautions Under the Gun When refinishing a surface your spray gun is one of the most important tools you will use What are some tips and tricks for using these spray guns What different types of paint guns are on the market What features do they offer Create a poster that illustrates these guns and tips and tricks for using them Auto Refinisher Job Ad You are the proud owner of a very prestigious auto body shop How
14. d provides corrosion protection 7 viscosity The thickness of a substance PRE PROGRAM DISCUSSION QUESTIONS 1 What do you think are the steps you would have to take to prepare a surface for refinish ing Why would each of these steps be important 2 What kinds of factors do you think could cause a paint job to turn out blemished imper fect or incorrect What do you think you can do to avoid or adjust for these factors 3 What tools and substances do you think are used by auto body repair technicians when preparing a surface for refinishing and actually performing the refinishing 4 What do you think are some important considerations for the environment area you are in when you apply a finish to a car Why do you think these are important 5 What do you think would be some of the biggest challenges you would face when refinish ing a surface Why POST PROGRAM DISCUSSION QUESTIONS 1 What is the first step for preparing any vehicle for refinishing Why is this step so important 2 Where can you learn about the formula for the type of finish and paint code you are going to use What does the formula tell you If paint doesn t match where can you get sug gestions on how to alter a paint color to more closely match a vehicle 3 Name three methods for removing cracked loose or blistering paint and the substances or tools these methods may require Which of these methods is best for large amounts or multiple layers of paint W
15. edures Refinish rigid semi rigid and flexible plastic parts E Clean condition and refinish vinyl e g upholstery dashes and tops Apply multi stage tricoat coats for panel blending or overall refinishing Identify and mix paint using a formula Identify poor hiding colors determine necessary action Tint color using formula to achieve a blendable match Identify alternative color formula to achieve a blendable match General Operations Identify parts using industry terminology 2004 Automobile Program Standards by the National Institute for Automotive Service Excellence ASE Copyright 2004 Reprinted with permission Language Arts and Communication Standards According to ASE NATEF standards the automobile technician must be proficient in the follow ing Language Arts and Communications related academic skills that are embedded in the occu pation The activities and information presented in this program and accompanying teacher s guide are aligned to the following standards from the National Automotive Technicians Education Foundation from the National Institute for Automotive Service Excellence Request collect comprehend evaluate and apply oral and written information gathered from customers associates and supervisors regarding problem symptoms and potential solutions to problems Identify the purpose for all written and oral communication and then choose the most effective strate
16. erfectly This program will use a vehicle with a panel repair to demonstrate the entire process of preparing sanding priming sealing topcoating clearcoating quality checking and final detailing It will also demonstrate a total refinish After viewing this video and completing some of the learning activities included in this guide students will be better prepared to properly complete surface preparation and refinishing and incorporate industry terminology in order to communicate effectively with coworkers parts suppliers and insurance adjusters MAIN TOPICS Topic 1 Preliminary Preparation amp Refinishing Process This section of the program describes the preliminary preparation required for finishing an autobody repair Students will learn the importance of cleaning before painting what to look for and how to evaluate what must be done to a surface before refinishing how to evaluate 5 the existing finish and color matching Topic 2 Surface Preparation This section of the program describes procedures for preparing a surface for refinishing Students will learn how to properly remove cracked or blistered paint how to use chemical stripper proper blasting sanding and grinding techniques how to apply primer surfacer and how to properly mask a vehicle for painting Topic 3 Applying the Finish This section describes the procedures for applying a final finish to an auto body repair Students will learn the four main
17. es atomization mean A Atomization means using compression to form paint into a cloud of tiny uniform droplets Feedback Atomization is very important to the success of a paint job It means that the paint is formed into a cloud of tiny uniform droplets When applied to a vehicle these droplets flow together to form a continuous film on the surface Q Before the color coat a sealer must be applied to the repair area and slightly beyond True or False A True Feedback The purpose of the sealer is to improve the adhesion of the new finish and to keep the finish from soaking into the porous surfacer causing color or texture variations Q When performing overall refinishing begin painting with the a roof b doors c hood d none of the above A a Feedback Overall refinishing works in a similar manner to panel repair but the entire surface of the car must be prepared before it can be painted Begin painting with the roof Hold the gun perpendicular to the surface and maintain even overlapping strokes Always move to a new area of the car from a wet edge ADDITIONAL RESOURCES WEB SITES AutoBody101 com http www autobody101 com Auto Body Curriculum Guide www sasked gov sk ca docs paa autobody index html 12 Auto Body Online www autobodyonline com Auto Body PI www autopi com frame htm Auto Body Pro www autobodypro com Auto Body Tool Mart Repair and Restoration Tutorials www autobodytoolmart com
18. ever your best auto body refinisher has just retired and you need to find a replacement Prepare a job advertisement to put in the newspaper or on the Internet that describes the skills knowledge experience and abilities you would want your replacement auto body refinisher to have INTERNET ACTIVITIES Teach Me Web Scavenger Hunt It s your turn to play the role of teacher Your job is to teach the class all about surface prepa ration and refinishing using only information you find on the Internet Prepare a lesson plan that uses a series of Web sites that you could use to teach the topic Your lesson plan should include at least three unique lessons about surface preparation and refinishing For each les son list the Web site what information it contains and how you would use that information to teach the class about surface preparation and refinishing When you are finished present 9 at least one of your lessons to the class Painting 101 Visit http www autobody101 com to learn about Auto Body and Paint Information Tips and Techniques Using this website choose at least three new tips and tricks and create a poster or booklet describing each of these tips and tricks For each tip or trick be sure to describe the following e What the tip or trick is and what part of the surface preparation and refinishing process it applies to e The tools needed for the tip or trick e What types of new benefits the tip or t
19. gies for listening reading speaking and writing to facilitate the communica tion process Adapt a reading strategy for all written materials e g customer s notes service manuals shop manuals technical bulletins etc relevant to problem identification diagnosis solu tion and repair E Use study habits and techniques i e previewing scanning skimming taking notes etc when reviewing publications shop manuals references databases operator s manuals and text resources for problem solving diagnosis and repair E Write clear concise complete and grammatically accurate sentences and paragraphs E Write warranty reports and work orders to include information regarding problem resolution and the results of the work performed for the customer or manufacturer E Follow all oral written directions that relate to the task or system under study Comprehend and apply industry definitions and specifications to diagnose and solve 4 problems in all automotive systems and components of the automobile and light truck E Comprehend and use problem solving techniques and decision trees that are contained in service manuals and databases to determine cause and effect relationships Use the service manual to identify the manufacturer s specifications for system parameters operation and potential malfunctions E Supply clarifying information to customers associates parts supplier and supervisors Standards for the
20. hat is the drawback to this method 4 What is masking Why is it important Describe five different types of materials used for masking Where should you get these materials Why 5 Describe the process for final detailing of a car What elements should you look for How can imperfections be fixed What steps should you take before returning the vehicle to its owner GROUP ACTIVITIES OOPS Poor Paint Jobs If you arent careful there are many things that can cause flaws in your final finish and require you to redo the job Review the video and think about the many different considerations ele ments and materials that could cause a paint job to go wrong Using paint and several com mon items such as glue dust candle wax paint that is too thick grease or other items cre ate a display of at least five poor paint jobs For example you can mix paint with dust or dirt and show the result when it dries For each poor paint job describe the material or mis take that caused the poor paint job and the steps that should be taken to ensure this type of result does not happen when applying a finish The Perfect Paint Booth There are four major considerations when applying a final finish A clean environment tem perature and humidity light and ventilation A good paint booth can help control these fac tors and provide the right environment for a good paint job As a group design your perfect Paint Booth Discuss how it would
21. rick offers e How the tip or trick is different or new Autobody Refinisher Career Profile Using the Internet research the career of an autobody refinisher How in demand is this career right now Is it growing What would you need to get started in this career What skills does it require Where can someone go to get those skills Prepare a report that details the autobody refinisher career Be sure to include statistics or research that talks about the career of autobody refinisher how it is growing what the cur rent salary is and how much of a demand exists for this career nationwide ASSESSMENT QUESTIONS Q What are the stages in the refinishing process a Cleaning checking applying the finish final detailing b Preliminary preparation cleaning surface preparation painting final detailing c Preliminary preparation surface preparation applying the final finish and final detail ing d None of the above A c Feedback There are four stages to the refinishing process Preliminary preparation which includes things like evaluating the existing finish and color matching surface preparation which includes getting the vehicle ready to paint applying the final finish and final detailing Failure to thoroughly follow any of the steps leading up to and including the final detailing can lead to a time consuming and money wasting disaster Q During preliminary preparation what is the next step after washing
22. ring devices Part of the series Shop Safety A Shopware Production 14 Order 20463 www cambridgeeducational com 1 800 468 4227 Automotive Technicians VHS DVD Cambridge Educational Sponsored by the National Automotive Technicians Education Foundation NATEF this pro gram explores automobile repair and collision repair NATEF works closely with Automotive Service Excellent ASE the nation s only industry wide certification program for automotive technicians Technicians with a sound education have a choice of career avenues Aside from fixing cars and trucks they can become service managers service engineers automotive writers or even auto technology teachers Order 24924 www cambridgeeducational com 1 800 468 4227 Understanding Cars VHS DVD Films for the Humanities and Sciences First they revolutionized travel Then they reshaped American culture This program narrated by Jane Curtin traces the history of automobile technology and design through the 20th cen tury Stops along the way include visits to the Sandia National Laboratories the GM Design Center the Detroit Car Show and the Petersen and Blackhawk Automotive Museums The mechanics of four stroke and two stroke internal combustion engines energy efficient vehi cles that run on electricity and fuel cells automated highways and smart cars and a number of automotive curiosities are featured Order 29881 www films com 1 800 257 5126 15 SHOPWARE
23. sealer must be applied to the repair area and slightly beyond The purpose of the sealer is to improve the adhesion of the new finish and to keep the finish from soaking into the porous surfacer causing color or texture variations When finishing plastic parts like a bumper cover you must add a flexing agent to the color and clear coats If you don t when the plastic flexes the finish might crack VOCABULARY TERMS atomization The breaking down of a liquid into small particles like a mist by the use of pressure cratering Erosion of the original finish digital mil gauge Digital device used to check finish thickness before during and after refinishing The device instantly shows a reading when it is placed next to a metal panel dry guide coat A fine dark colored dust used to determine if a surface is smooth and level featheredge The technique of gradually tapering one finish into the other masking to cover up as in prior to painting pencil mil gauge Device used to check finish thickness before during and after refinishing To use the magnetic end is placed against the metal body As it is slowly pulled away a reading is registered primer surfacer Also called surfacer A substance that fills in scratches left by sanding and grinding and other little imperfections in the body filler and provides a good base for the adhesion of finish coats self etching primer A substance that promotes paint adhesion an
24. suitable sealer to the area being refinished when sealing is needed or desirable Scuff sand to remove nibs or imperfections from a sealer Spray Gun and Related Equipment Operation Inspect clean and determine condition of spray guns and related equipment air hoses regulators air lines air source and spray environment E Check and adjust spray gun operation for HVLP high volume low pressure or LVLP low volume low pressure guns Set up fluid needle nozzle and cap adjust and test spray gun using fluid air and pattern control valves Paint Mixing Matching and Applying Determine type and color of paint already on vehicle by manufacturer s vehicle information label Shake stir reduce catalyze activate and strain paint according to manufacturer s procedures Apply finish using appropriate spray techniques gun arc gun angle gun distance gun speed and spray pattern overlap for the finish being applied 3 E Apply selected product on test and let down panel in accordance with manufacturer s rec ommendations check for color match Apply single stage topcoat for refinishing Apply basecoat clearcoat for panel blending or partial refinishing Apply basecoat clearcoat for overall refinishing E Denib buff and polish finishes where necessary Identify the types of rigid semi rigid or flexible plastic parts to be refinished determine the materials preparation and refinishing proc
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