32405306Collision Structural Welding & Panel Replacement
Course Information
Description
Structural damage analysis, measuring vehicle dimensions, pulling and straightening vehicle structures. Replacement and alignment of non-structural panels will be performed on vehicles. Collision structural section joints will be constructed and welded (GMAW).
Total Credits
5
Course Competencies
  1. Demonstrate personal safety and use protective material to ensure vehicle safety while completing structural repairs
    Assessment Strategies
    Skill Demonstration
    Criteria
    Identify protective material used in the collision shop
    Cover vehicle with welding blanket
    Research OEM service information on weld precaution
    Remove computer modules in immediate weld locations
    Remove interior in immediate weld location
    Identify grinding sparks direction

  2. Identify equipment used to straighten collision structural damage
    Assessment Strategies
    Skill Demonstration, Verbal, and/or Test
    Criteria
    Identify various styles of pulling clamps
    Describe the purpose of a pulling tower
    Identify a porta-power
    Describe chain capacity
    Identify towel capacity
    Identify a fixture system
    Identify a frame bench
    Identify pressure gauges
    Explain the use of straps
    Identify chain binders
    Identify a tram gauge
    Identify a tape measure
    Identify safety chains
    Identify 3D measuring equipment
    Identify hand tools used in the collision shop

  3. Measure a vehicle
    Assessment Strategies
    Skill Demonstration
    Criteria
    Use a tape measure and tram gauge (analog)
    Measure control points on a vehicle
    Use a computerized measuring system
    Computerized measuring system identifies the damage
    Explain the next steps in repairing the vehicle

  4. Section a vehicle rail
    Assessment Strategies
    Skill Demonstration
    Criteria
    Demonstrate effective cutting, spot weld removal, measuring, test fitting, welding (MIG and spot) and grinding
    Rail must fit a gig when finished

  5. Attach vehicle to frame straightening equipment
    Assessment Strategies
    Skill Demonstration, Verbal, and/or Test
    Criteria
    Differentiate body over frame construction compared to unitized structure
    Research full frame sectioning procedures
    Interpret service information
    Identify body mount replacement
    Identify kink vs bend rule
    Identify tools and equipment required for sectioning
    Identify electrode wire and size needed for welding
    Identify weld method and pattern
    Identify joint method
    Complete sectioning joint
    dress welds.
    add corrosion protection in the sectioning joint after repairs.
    do post inspection.

  6. Replace welded panel from a vehicle
    Assessment Strategies
    Skill Demonstration, Verbal, and/or Test
    Criteria
    Identify part to be replaced at factory joint
    Research OEM replacement procedure
    Interpret replacement procedure
    Select correct tools needed for replacement at factory joint
    Remove damaged structural component
    Trim service part
    Verify replacement part is in the correct spot using 3D measuring
    Use the correct joint
    Use the correct joining process
    Dress the joint
    Add corrosion protection to the new serviced part
    Complete post inspection of the replacement area.
    Replaced panel is ready for the pain prep process

  7. Repair damaged structural parts
    Assessment Strategies
    Skill Demonstration
    Criteria
    Demonstrate sheet metal repair
    Use OEM recommended procedures
    Repaired panel is ready for priming operations

  8. Identify vehicle dimension correction before, during, and after repair
    Assessment Strategies
    Skill Demonstration, Written Product
    Criteria
    Research dimension sheets
    Interpret symbols on dimension sheet
    Interpret reference point on a dimension sheet
    Identify equipment used for measuring vehicle dimensions
    Measure vehicle for dimensional correctness
    Compare measurements to actual vehicle dimensions
    Determine amount of structural movement using measurement comparison
    Convert milometers to inches
    Pull structural damage to measure correctly
    Monitor structural movement with measurements

  9. Restore corrosion protection of compromised repair locations
    Assessment Strategies
    Skill Demonstration
    Criteria
    Identify corrosion protective material and application
    Identify corrosion protection material characteristics
    Research OEM recommendation for corrosion protection material replacement
    Interpret OEM recommendation for corrosion protection material replacement
    Select the correct corrosion protection application
    Calculate the correct amount of corrosion protection needed for application
    Set up corrosion protection applicator effectively
    Research technical data sheet for corrosion protective material
    Interpret TDS information
    Apply various corrosion protective material to mock up

  10. Demonstrate steps for door skin replacement
    Assessment Strategies
    Skill Demonstration
    Criteria
    Remove door from vehicle
    Remove and protect interior door components
    Grind off door skin lip
    Use heat gun to loosen adhesive
    Remove door skin
    Prep door skin for adhesive
    Prep door shell for adhesive
    Follow technical data sheet for adhesive application
    Apply adhesive effectively
    Join door skin to door shell
    Create door hem flange
    Install door on vehicle to adjust door skin
    Remove door and finish hem flange
    Create any additional attachment method used to hold door skin in place
    Add corrosion protection

  11. Demonstrate steps for truck box side replacement
    Assessment Strategies
    Skill Demonstration
    Criteria
    Research service information for box side replacement
    Remove truck box from vehicle
    Remove and protect additional truck box components
    Remove box side attachments (bolts, welds, rivets, and adhesives)
    Use heat gun to loosen adhesive
    Remove box side from truck box
    Prep box side for adhesive
    Prep truck box for adhesive
    Follow technical data sheet for adhesive application
    Apply adhesive effectively
    Join box side to truck box
    Create any additional attachment method used to box side in place
    Add corrosion protection

  12. Perform structural steel welding
    Assessment Strategies
    Skill Demonstration
    Criteria
    Perform welds that visually and destructively meet industry standards
    Set up welder correctly for structural steel
    Weld using collision industry joint techniques
    Weld using gun position methods for overhead welding
    Weld in an overhead position on 18-gauge steel

  13. Perform squeeze type resistant spot welds (STRSW)
    Assessment Strategies
    Skill Demonstration
    Criteria
    Describe the STRSW process
    Set up welding equipment according to manufacturers' specifications for the metal being welded
    Perform welds that visually and destructively meet industry standards
    Interpret instruction manual and procedure
    Identify weld failure
    Perform multi layer welds