automotive body engineering

7/29/2019 Automotive Body Engineering

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This damageon the

original

vehicle hasto be

repaired!

Basic principles in bodywork processing

Which methods

can be used to

repair the

damage?

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The various repair options should be discussed in the theoretical preliminary talks.

Solution suggestions!1. ___________________________________________________________

2. ___________________________________________________________

3. ___________________________________________________________

4. ___________________________________________________________

Student Edition


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Tools needed for basic bodywork

repair.


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Information!

The activities shown in the following represent a didactically prepared repairjob on a section of a sillboard.

It is essential that the teacher or trainer is qualified in bodywork processing.

It is a good idea if this work is carried out at least once by this teacher himself.

This also applies to the other basic subjects, such as panel beating

techniques, adhesion of panes, adhesion of sheet metal and plasticsprocessing.


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Sample sillboard

The system shown above was developed so that students can carry outa practical repair themselves.

All of the work shown in the following illustrations can be carried out.


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Picture 1 2

3 4

1. Bodywork processing (Section repair) What do the pictures show ?

1 ____________________________________________

2 ______________________

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3 ______________________

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4 ______________________

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8

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5 ________________________

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6 ________________________

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7 ________________________

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8 ________________________

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9 _______________________________________

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11 _______________________________________

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10 __________________________________________

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12 __________________________________________

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9

1112

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14 ________________________

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16

14 _______________________________

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15 ________________________

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16 _______________________________

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13 14


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17 and 17a

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Risk of accident:

Use protective

welding equipment .

18

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19

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Risk of accident:

Wear protective goggles, leather gloves and, as

necessary, ear protection. Beware of flying sparks.

17

17 a

18

19


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20

________________________________

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21

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and

22

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Risk of accident:

Make sure that the newsection is securely clampedwhen cutting.

20 21

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Note:see item 14

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Note:see item 19

30 and 31

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____________________________________________________________

______________________________

Caution:

High temperatures will cause

warping.

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Risk of accident:

Use protectivewelding equipment.

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Risk of accident:See item19

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Risk of accident: See item19

3637

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40

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Making and fitting the section!

The section can

be _____________

________________

Drawing out techniques!

Tin loop, ______________________

Bumping work

2. Work techniques in sheet forming


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Tool selection _____________ ______________________________________

Depending on the requirements,

the teacher is given a wide range

of possibilities to achieve hisdidactic targets.


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Deformation

behaviour on

exposure to

heat etc.

e.g. ___________________

e.g. _________________


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Resistance shrinking with carbon electrode


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3.

Adhesion of sheetsAs the illustrations for panel beating show, the

same basic frame can be used to carry outsheet adhesion work using the example of anadhesion repair (hiere: on the filler neck of a

fuel tank) with readily available repair sets.

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4.

Plastics processing

Various plastics repairs can becarried out here using

commercially available repairsystems.

TIP! Use old bumpers from scrap.

e.g. ___________________

e.g. ___________________

e.g. ___________________

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5.

Adhesion of panes

Adhesion of panes can be carried outin accordance with the repairguidelines of the manufacturer

(here Fiat Lancia).

TIP! Commercially available repair systemscan also be used here.

automotive body engineering

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