32405303Non-Structural Panel Repair & Glass Servicing
Course Information
Description
Further development of straightening skills and sheet metal alignment is achieved by performing these activities on automobiles. Such operations as straightening damages sheet metal on fixed parts and removable panels are performed. Instruction on the replacement of fixed glass such as windshields, rear window, and side glass is covered using industry standards. Further instruction includes the components and procedures involved in the removal and installation of movable glass.
Total Credits
5
Course Competencies
  1. Demonstrate workplace and personal safety
    Assessment Strategies
    Skill demonstration in shop
    Criteria
    Select and use proper personal safety equipment; take necessary precautions with hazardous operations and materials in accordance with federal, state, and local regulations.
    Locate OEM procedures to identify material and composition of the vehicle being repaired (mild steel, high strength steel, ultra-high strength steel, aluminum, stationary glass, etc.)
    Locate procedures and precautions that may apply to the vehicle being repaired, including materials used in the repair.
    Perform vehicle clean-up; complete quality control using a checklist on operations performed.
    Determine telematic/connectivity of the vehicle and recognize the need to place vehicle in service mode.
    Demonstrate knowledge of hazards related to high voltage systems/electric vehicles, including electrocution, fire, explosion, arc flash, gasses and fumes, hazardous chemicals, and EMF, and how to properly respond to emergency situations.

  2. Perform damage analysis on a vehicle
    Assessment Strategies
    Skill demonstration in shop
    Criteria
    Analyze damage to determine appropriate repair methods in accordance with manufacturer's recommendations and guidelines. HP-G
    Determine the direction, point(s) of impact, and extent of direct, indirect, and inertia damage. HP-G
    Gather details of the incident/accident necessary to determine the full extent of vehicle damage. HP-G
    Identify and record pre-existing damage. HP-G
    Identify and record prior repairs. HP-G
    Determine parts, components, material type(s) and procedures necessary for a proper repair. HP-I
    Identify type and condition of finish; determine refinish labor operations as required. HP-I
    Identify suspension, electrical, and mechanical component physical damage. HP-G
    Identify safety systems physical damage. HP-G
    Identify interior component damage. HP-G
    Identify add-on accessories and modifications. HP-G
    Perform a prescan; identify and document illuminated dash malfunction indicator lamp(s) (MIL) and stored diagnostic codes. HP-I

  3. Prepare vehicle surfaces
    Assessment Strategies
    Skill demonstration in shop
    Criteria
    Inspect, remove, store, protect, and replace exterior trim and components necessary for proper surface preparation. HP-I
    Soap and water wash entire vehicle; use appropriate cleaner to remove contaminants. HP-I
    Soap and water wash entire vehicle; complete pre-repair inspection checklist. HP-I
    Prepare damaged area using water-based and solvent-based cleaners. HP-I
    Remove corrosion protection, undercoating, sealers, and other protective coatings as necessary to perform repairs. HP-I
    Inspect, remove, and reinstall repairable plastics and other components for off-vehicle repair. HP-I

  4. Prepare for non-structural analysis and damage repair (body components)
    Assessment Strategies
    Skill demonstration in shop
    Criteria
    Perform a prescan; identify and document illuminated dash malfunction indicator lamp(s) (MIL) and stored diagnostic codes. HP-I
    Review damage report and analyze damage to determine appropriate methods for overall repair; develop and document a repair plan. HP-I
    Inspect, remove, protect, label, store, inventory, and reinstall exterior trim and moldings. HP-I
    Inspect, remove, protect, label, store, inventory, and reinstall interior trim and components. HP-I
    Inspect, remove, protect, label, store, inventory, and reinstall body panels and components that may interfere with or be damaged during repair. HP-I
    Inspect, remove, protect, label, store, inventory and reinstall vehicle mechanical and electrical components that may interfere with or be damaged during repair. HP-G
    Protect panels, glass, interior parts, and other vehicles adjacent to the repair area. HP-I
    Soap and water wash entire vehicle; complete pre-repair inspection checklist. HP-I
    Prepare damaged area using water-based and solvent-based cleaners. HP-I
    Remove corrosion protection, undercoating, sealers, and other protective coatings as necessary to perform repairs. HP-I
    Inspect, remove, and reinstall repairable plastics and other components for off-vehicle repair. HP-I

  5. Inspect suspension and steering components
    Assessment Strategies
    Skill demonstration in shop
    Criteria
    Perform visual inspection and measuring checks to identify steering and suspension collision damage. HP-G
    Identify one–time use fasteners. HP-I
    Clean, inspect, and prepare reusable fasteners. HP-I
    Reinstall wheels and tighten lug nuts to manufacturers spec using a torque wrench. HP-I

  6. Evaluate electrical components for repair or replacement
    Assessment Strategies
    Skill demonstration in shop
    Criteria
    Demonstrate an understanding of Ohm's Law. HP-I
    Check for available voltage, voltage drop and current, and resistance in electrical wiring circuits and components with a DMM (digital multimeter). HP-I
    Repair wiring and connectors. HP-G
    Inspect, test, and replace fusible links, circuit breakers, and fuses. HP-I
    Perform battery state-of-charge test and slow/fast battery charge. HP-I
    Inspect and clean or replace battery, battery cables, connectors and clamps. Remove, replace, and recharge battery. HP-I
    Dispose/recycle batteries according to local, state, and federal requirements. HP-G
    Check operation and aim headlamp assemblies and fog/driving lamps; determine needed repairs. HP-G

  7. Analyze vehicle construction and parts
    Assessment Strategies
    Skill demonstration in shop
    Criteria
    Identify type of vehicle construction (unibody, body-over-frame). HP-G
    Recognize the different collision damage between unibody and body-over-frame vehicles. HP-G
    Identify impact energy absorbing components. HP-G
    Identify different types and strengths of substrates (steel types, aluminum, magnesium, plastic, composites, etc.) HP-G

  8. Prepare for non-structural repair
    Assessment Strategies
    Skill demonstration in lab
    Criteria
    Inspect, remove, protect, label, store, inventory, and reinstall exterior trim and moldings. HP-I
    Inspect, remove, protect, label, store, inventory, and reinstall interior trim and components. HP-I
    Inspect, remove, protect, label, store, inventory, and reinstall body panels and components that may interfere with or be damaged during repair. HP-I
    Inspect, remove, protect, label, store, inventory, and reinstall vehicle mechanical and electrical components that may interfere with or be damaged during repair. HP-I
    Protect panels, glass, interior parts, and other vehicles adjacent to the repair area. HP-I
    Soap and water wash entire vehicle; complete pre-repair inspection checklist. HP-I
    Prepare damaged area using water-based and solvent-based cleaners. HP-I
    Remove corrosion protection, undercoating, sealers, and other protective coatings as necessary to perform repairs. HP-I
    Inspect, remove, and reinstall repairable plastics and other components for off-vehicle repair. HP-I

  9. Evaluate moveable glass and hardware for repair or replacement
    Assessment Strategies
    Skill demonstration in shop
    Criteria
    Inspect, adjust, overhaul, repair or replace window regulators, run channels, glass, power mechanisms, and related controls. HP-I
    Inspect, adjust, repair, remove, reinstall or replace weather-stripping. HP-G
    Inspect, remove, repair or replace, and adjust removable power operated roof panel and hinges, latches, guides, handles, retainer, and controls of sunroofs. HP-G

  10. Perform metal welding, cutting, and joining
    Assessment Strategies
    Skill demonstration in shop
    Criteria
    Determine the correct GMAW welder type, electrode/wire type, diameter, and gas to be used in a specific welding situation. HP-I
    Set up, attach work clamp (ground), and adjust the GMAW welder to "tune" for proper electrode stickout, voltage, polarity, flow rate, and wire-feed speed required for the substrate being welded. HP-I
    Store, handle, and install high-pressure gas cylinders; test for leaks. HP-I
    Determine the proper angle of the gun to the joint and direction of gun travel for the type of weld being made. HP-I
    Protect adjacent panels, glass, vehicle interior, etc. to prevent damage from welding and cutting operations. HP-G
    Identify hazards; foam coatings and flammable materials prior to welding/cutting procedures. HP-G
    Protect computers and other electronics/wires prior to welding procedures. HP-G
    Clean and prepare the metal to be welded, assure good metal fit-up, apply weld-through primer if necessary, and clamp or tack as required. HP-I
    Determine the joint type (butt weld with backing, lap, etc.) for weld being made. HP-I
    Determine the type of weld (continuous, stitch weld, plug, etc.) for each specific welding operation. HP-I
    Perform the following welds: plug, butt weld with and without backing, and fillet etc., in the flat, horizontal, vertical, and overhead positions. HP-I
    Perform visual evaluation and destructive test on each weld type. HP-I
    Identify the causes of various welding defects; make necessary adjustments. HP-I
    Identify cause of contact tip burn-back and failure of wire to feed; make necessary adjustments. HP-G
    Identify cutting process for different substrates and locations; perform cutting operation. HP-I
    Perform rivet bonding procedures. HP-I
    Dress/grind weld as needed.

  11. Perform outer body panel repairs, replacements, and adjustments
    Assessment Strategies
    Skill demonstration in shop
    Criteria
    Inspect/locate direct, indirect, or hidden damage and direction of impact. HP-I
    Inspect, remove and replace welded steel panel or panel assemblies. HP-G
    Determine the extent of damage to aluminum body panels; repair or replace. HP-G
    Inspect, remove, replace, and align hood, hood hinges, and hood latch. HP-I
    Inspect, remove, replace, and align deck lid, lid hinges, and lid latch. HP-I
    Inspect, remove, replace, and align doors, latches, hinges, and related hardware. HP-I
    Inspect, remove, replace and align tailgates, hatches, and liftgates. HP-
    Inspect, remove, replace, and align sliding doors. HP-G
    Inspect, remove, replace, overhaul, and align bumpers, covers, reinforcements, guards, impact absorbers, and mounting hardware. HP-I
    Inspect, remove, replace and align fenders, and related panels. HP-I
    Restore corrosion protection during and after the repair. HP-I
    Replace seam sealer to match OEM appearance. HP-I
    Identify one-time use fasteners. HP-G
    Weld damaged or torn steel body panels; repair broken welds. HP-G
    Inspect and identify labels/decals and replace as necessary. HP-G

  12. Perform non-structural repair on outer body panels
    Assessment Strategies
    Skill demonstration in shop
    Criteria
    Inspect, remove, replace, and align hood, hood hinges, and hood latch. HP-I
    Inspect, remove, replace, and align deck lid, lid hinges, and lid latch. HP-I
    Inspect, remove, replace, and align doors, latches, hinges, and related hardware. HP-I
    Inspect, remove, replace, and align tailgates, hatches, and liftgates. HP-I
    Inspect, remove, replace, and align sliding doors. HP-G
    Inspect, remove, replace, overhaul, and align bumpers, covers, reinforcements, guards, impact absorbers, and mounting hardware. HP-I
    Inspect, remove, replace, and align fenders and related panels. HP-I
    Restore corrosion protection during and after the repair. HP-I
    Replace seam sealer to match OEM appearance. HP-I
    Restore sound deadeners and foam materials. HP-G
    Identify one-time use fasteners. HP-I
    Inspect and identify labels/decals and replace as necessary. HP-G
    Follow manufacturers guidelines when applying heat to non-structural components during repair. HP-G

  13. Demonstrate metal finishing and body filling
    Assessment Strategies
    Skill demonstration in shop
    Criteria
    Prepare a panel for body filler by abrading or removing the coatings; featheredge, refine scratches, and clean the surface before the application of body filler. HP-I
    Locate and repair surface irregularities and straighten contours on a damaged body panel using power tools, hand tools, and weld-on pulling attachments. HP-I
    Demonstrate hammer and dolly techniques. HP-I
    Heat shrink stretched panel areas to proper contour. HP-G
    Cold shrink stretched panel areas to proper contour. HP-I
    Identify body filler defects; correct the cause and condition. (Pinholing, ghosting, staining, over catalyzing, etc.) HP-I
    Identify different types of body fillers. HP-G
    Shape body filler to contour; finish sand. HP-I
    Locate and repair surface irregularities and straighten contours on a damaged panel using Glue-Pulling Dent Repair (GDPR). HP-G
    Mix and apply body filler. HP-I