BOOK 2; VOLUME 4 (EXTRA)

Why should you avoid using a cutting torch to cut out a replacement panel?

Because a cutting torch tends to leave ragged edges and surrounding metal may be distorted by the heat.

Why is it better to remove a hood when you are repairing panel damage?

Because it is much easier to repair the damage if you remove the hood from the vehicle and place it in a holding device.

Why should the catalyst be the last item added to the resin?

Because the chemical reaction starts immediately.

Where would you find the most stress on a vehicle's frame?

Center.

What tool do you use for removing broken pieces of glass from channels?

Chisel.

What should you do to prevent dust and grit from possibly sticking to the face of a bumping hammer during a bumping operation?

Clean the metal.

How can you align or reposition a fender?

By loosening the attaching bolts.

State how you should add a catalyst and promoter to resin.

Add only one at a time and never mix the two together.

State one way to avoid scratching the surface when working with glass?

Always lay glass on surfaces protected by cloth, paper, or other soft material.

What happens when you mix a catalyst and promoter together?

An explosion will occur.

At what angle should you maintain the face of the sander to the metal surface for grinding?

Approximately 10* to 20*.

Name five small hand tools you use in glass repair.

- Pliers. - Pullers. - Glasscutters. - Channel driver. - Chisel. - Rubber mallet. - Handle-clip tools. - Phillips offset ratchet. - Window seal installation kit.

List two methods for checking the fit and alignment of a deck lid?

- Rub chalk around the flange of the lid, close the lid, and then open the lid and check the weather stripping. The chalk leaves marks on the weather stripping and easily indicates any spots that do not fit. - Close the deck lid on strips of paper and then attempt to pull them out.

What can result if you do not follow the repair sequence?

- Stretched metals. - Cracks. - Breaks. - Additional unnecessary work.

Match the misalignment type in column B with the description in column A. The types in column B may be used once, more than once, or not at all. Column A 1.) An impact to the left side of the vehicle. 2.) A parallel impact to the front. 3.) Overloading the vehicle's frame. 4.) An impact to the right side of vehicle. 5.) A parallel impact to the rear. Column B a. Sway. b. Diamond. c. Tracking. d. Sag.

1. a. 2. b. 3. d. 4. a. 5. b.

What tools do you use to straighten a bowed-in center body pillar?

A hydraulic body jack with a rubber flex head and extension tubes.

What do you use to determine the correct curvature of a center pillar?

A template.

List three tools you can use in removing the outer rocker panel in order to access the inner rocker panel.

- A hacksaw. - A small rotary saw. - A cutting torch.

What tools can you use for applying body filler?

- A hard rubber paddle (squeegee). - Putty knife. - Other device that enables you to apply the filler smoothly.

What three types of hammers do you use in body repairs?

- Bumping. - Dinging. - Pick.

What three auto body tools may be replaced by a body spoon?

- Dolly block. - Driving tool. - Pry tool.

List the PPE you should use when working with fiberglass.

- Face shield. - Goggles. - Rubber apron. - Rubber gloves. - Respirator.

Which reinforcements are used in door panels and floor pans, and serve as structural members?

- Formed reinforcements include flanges, grooves, ridges on the inside of the door panels and on floor pans. - Welded-on reinforcements are normally box sections or channels and occur as crossbars on the underside of the floor pan, roof rails under the hood or deck lid, and in many other places.

What are some conditions you should look for during your preliminary inspection of a frame?

- Kinks, bends, rips or tears on the side members. - Loose rivets, bolts and body support brackets. - Cracks in the welded connections.

List the four basic crowns.

- Low-crown. - High-crown. - Combined high- and low-crown. - Reverse crown.

Why must the mixing surface for filler be completely clean and free of oil, grease, and dirt?

Because they can adversely affect the chemical properties of the plastic.

How should you bevel a fiberglass component that has both sides accessible?

Bevel one-third of the total depth on each side.

Which hammer spreads the force of impact over a large area?

Bumping.

How can you minimize the distortion of a welded replacement panel?

By using the GMAW welding process and staggering the welds from one side to the other around the entire panel.

How can you adjust the curing time for plastic filler?

By varying the amount of catalyst mixed with the resin.

Before you order any abrasive discs, what should you do first?

Consult the operator's manual that comes with the disc sander or measure across the disc to determine its size.

What must you do before starting to remove any distortion a body panel received in a collision?

Determine the direction the damaging force came from and the point at which contact was made.

Which hammer do you use to prevent overstretching a metal surface?

Dinging.

What is the purpose of transferring the measurements to the floor?

Facilitate making measurements with greater ease and more accuracy.

Which center section component provides main structural support for the passenger compartment?

Floor pan.

What allowances must be made where glass is subject to considerable changes in temperature?

For its expansion and contraction.

What do you call the side member extensions used to support front and rear bumpers on most vehicles?

Frame horns.

In which body section can the firewall be found?

Front section.

What do you use to edging, such as rough grinding to polishing the glass?

Glass edging machines.

What device allows you to remove window channels without bending or buckling them?

Glass vise.

Which method specifies that you place the dolly block close to but away from the area where the hammer will strike?

Hammer-off-dolly method.

What method do you use to increase the size of an area if you place the dolly block directly under the point where the hammer will strike?

Hammer-on-dolly method.

What spoon do you use for straightening buckles in low-crown areas?

High-crowned bumping spoon.

What conditions warrant the replacement of a new outer panel on a door?

If the inner panel and construction are reparable and undamaged.

Why must you order tempered glass for vehicles?

It cannot be cut and the windows must be the exact size and shape for their specific locations on the vehicle in question.

Describe the construction features of a spoon.

It is a bar of steel that is forged flatter at one end than the other or flatter at both ends than the middle. Spoons are bent into a variety of shapes depending upon their use.

Describe how you can determine if a hood is aligned properly.

It opens and closes easily, presents a smooth contour in relation to the adjoining sections (front panel or front fenders), matches the contour of the cowl panel perfectly, and has a uniform gap along each side for its full length.

What type of glass do you use for windshields?

Laminated glass.

What is the advantage of a unitized body-type construction for a passenger car?

Lighter weight.

How do you hold the bumping hammer when using a dolly block?

Lightly, letting you grip slacken as the hammer descends.

Describe the procedure for filling an area over 1/4-inch deep.

Make two or more applications, allowing each layer to set up before adding the next.

What are the two most difficult and critical procedures for cutting glass?

Making and cracking the cut in the glass.

Briefly describe a unitized body.

Manufacturing process where sheet metal body parts are combined with stress-bearing elements to form the body and chassis as a single piece, as opposed to attaching body parts to a frame.

What is the maximum allowable difference at intersecting points?

Measurements should not vary more than 1/8 inch at any point.

Should a dolly block weigh more or less that the hammer you are using?

More.

How can you correct minor misalignment on a door?

Move door hinges. Either the hinges or pillar posts have elongated holes that allow the hinges to be moved in, out, forward, or backwards.

Does a high-crown surface bend easily when you apply hand pressure?

No, high-crowns offer additional strength for resisting force.

Is it permissible to use polyester resin to repair metal surfaces?

No; polyester will not stick to metal satisfactorily. Epoxy resin is recommended for use.

What type of resin do manufacturers use in laminated glass?

PVB.

Briefly, state the sequence of events as they occur when a panel receives damage in a collision.

Panel damage starts with a minor dent caused by colliding objects. Next, a larger area caves in while a ridge buckles at the extreme edge of the same cave-in. As the colliding object moves further across or deeper into the body panel, the buckled-up ridge travels ahead in much the same way a wave travels ahead of a boat. As the collision reaches full intensity, this high ridge remains kinked up (locked) and becomes extreme outer ring of the damaged area. As the impact slows and stops, the damaged area springs back slightly but remains inflexible because of the locked ridge and inverted V-channels.

Describe the manufacturing process for tempered glass.

Rapidly heating the glass and then exposing both sides to cooling jets of air.

How is the Phillips offset ratchet used and what makes it effective for its purpose?

Removing screws in close quarters; because it has greater flexibility than the fixed-offset screwdriver.

What should you do if you notice dry-rot cracks on the sander's rubber disc?

Replace the disc because small pieces of hard rubber can fly off in any direction during operation of the sander and cause serious injury.

How are the cross member attached to the side members on a vehicle frame?

Riveted or welded.

What allows you to position a door handle in the most desirable or convenient location?

Serrated (notched) shaft with set set screws.

Name the most important part of a vehicle's frame.

Side members or side rails.

What materials are combined to make glass?

Silicon (sand), alkali (potash or soda), and either lead or lime.

How is the bumping spoon best used?

Straightening long, relatively smooth buckles where the distortion is comparatively light and spread out over a large area.

What are the two recommended methods for pulling out dents?

Suction cups and stud spot welds.

Briefly explain how you can shrink a stretched area using the cold-shrinking process.

Take a dolly with a groove in it an strike on the groove with a cross-peen hammer.

Describe how to cut a fiberglass mat when making a repair.

The fiberglass mat should be cut approximately 2 inches larger than the damaged area.

What would be the result if the filler starts "setting up" before application?

The filler would cake or roll up; additionally, it would tend to pull loose from the surface.

What can happen if you are not careful to bring down the raised metal first during a bumping operation?

The metal stretches and bends at such sharp angles that further correction is very difficult.

If special equipment is not available, what alternate method can you use to check frame alignment?

The plumb bob method.

How do the surface preparation procedures for fiberglass and plastic filler differ?

The preparation procedure is the same.

What happens when you add a catalyst to the resin?

The resin changes from a liquid to a solid--polymerization.

What size of torch tip do you use for hot shrinking?

The same size torch top you would use for welding metals of the same thickness.

Why are crowns used in vehicle bodies?

They help enhance the beauty and style of the automobile, while adding considerable strength and rigidity.

How can you speed up the curing time of a fiberglass repair?

Through the use of a heat lamp to apply a small amount of heat.

Why are frames narrower at the front?

To allow clearance for the front wheels during sharper turns.

What is the purpose of the fiberglass mat?

To build up as well as span damaged areas.

What is the reason for grinding and polishing window glass?

To eliminate any distortions.

What is the purpose of pick hammers?

To pick out small dents in panels and other hard-to-get-at places where you cannot use a dolly block.

Why should you follow step-by-step procedures during metal bumping operations?

To prevent new lines of strain as well as stretching and bending of metal.

Why should you straighten a panel area prior to the measuring operation when replacing/fabricating a panel?

To provide a more accurate measurement and allow you to know the exact amount of panel to cut.

Why is it necessary to quench the heated area when you perform hot shrinking?

To reduce the possibility of annealing the metal and to help shrink the metal.

What is the reason for using a promoter?

To serve as a drying agent; in other words, it prevents the resin surface from becoming tacky.

Which drawing is figure 1-10 show the correct use of a bumping hammer?

Top and bottom left drawings.

What is another term used for deck lid?

Trunk lid.

What must you do to the knot-like dents raised by using a pick hammer?

Use a body file to file them level with the body surface.

What should you use a rubber squeegee for when making a fiberglass repair?

Use a rubber squeegee to work out all air bubbles that become trapped.

When preparing a surface for filling, what safety equipment should you wear during grinding operations?

Use goggles, hearing protection, and respirators during any grinding operation. Wearing leather gloves when operating the sander is also advisable because the metal surface you are grinding can become very hot.

If you use a body file, how can you avoid undercutting?

Use light pressure during each stroke.

What will a low-crown do if you press and release it by hand?

Usually springs back to its original shape.

What one factor can cause the resin in laminated glass to decompose?

Very high temperatures.

What are some causes of frame misalignment?

When a vehicle is used for the wrong purpose (overloading, running over curbs or parking area concrete stops, and repeatedly operating on very rough terrain--unpaved roads or no roads) or is involved in an accident.

When can you use the basic caulking iron?

When straightening and reshaping short-radius bends on narrow, flat surfaces.

Why should you never move the sander disc into a corner where two pieces of metal come together to form a single joint?

You can lose control of the sander, seriously injuring yourself or someone standing nearby.

What will happen if you mix the catalyst and promoter together?

You will cause an explosion.

Briefly, describe each of the following damage conditions. a. Displace area. b. Upsets. c. Stretches. d. Simple bend. e. Buckle.

a. A displaced area is part of the damage only because it pushes out of position. b. An upset occurs when opposing forces apply pressure to an area of metal and cause it to yield. As the surface area reduces, the thickness increases proportionally. c. A stretched area is the exact opposite of an upset area. Tension, instead of pressure, causes stretching. This results in an increase in surface area. d. A simple bend is an area of metal that serves as a pivot for movement without breaking. e. A buckles is the result of a severe bend where the metal buckles or kinks up at the pivot point.