BODY REPAIR SHOP & CAR BODY SHELL AN OVERVIEW

Presented BYNAISHADH DESAISURVEYOR & LOSS ADJUSTER,SURATJULY 26, 2009AtM/S WELTECH MOTORSSURAT

SALIENT FEATURESAUTOMOBILE WORK SHOPACCIDENTSVEHICLEVEHICLE BODY SHELLBODY SHELL REPAIR SHOP.ACTIVITIES IN BODY REPAIR SHOP.EQUIPMENTS OF BODY REPAIR SHOPDEMO SEQUENCE OF DENT BEATING PROCESS

AUTOMOBILE WORK SHOP AN AUTOMOBILE WORKSHOP IS A ROOM / BUILDING / PREMISES WHICH PROVIDES BOTH AREA / SPACE & TOOLS / EQUIPMENTS, THAT MAY BE REQUIRED FOR REPAIR / MAINTANENCE ACTIVITY OF ANY AUTOMOBILE

MAJOR DIVISION OF AUTOMOBILE WORKSHOP

GENERAL MAINTENANCE REPAIR SHOP

VEHICLE WASHING, TUNING, PREVENTATIVE, ROUTINE AND MAJOR MAINATANANCE / REPAIR WORK FOR ENGINE, TRANSMISSION, BRAKE, ELECTRICAL, AIRCONDITIONING SYSTEM ETC OF AUTOMOBILE

BODY SHOPBODY SHELL REPAIR SHOP

DISMENTLINGGETTING RID OF RUSTCUTTING & WELDINGPANEL BEATINGDENT/REFABRICATIONREASSEMBLINGALTERATION / MODIFICATIONBODY SHELL PAINT SHOP

COMPLETE PAINT RELATED ACTIVITIES

ACCIDENT

SKILL REQUIRED BODY SHOP INCHARGE

Knowledge of Vehicle & its body Better understanding of job on handJob analysis skillProcess skillTechnology skillEquipment skillASSESSOR / CLAIM EXAMINAR

Knowledge of Vehicle & its body Better understanding of job on handJob analysis skillProcess skillTechnology skillEquipment skill

VEHICLE

BARE BODY SHELLTYPE OF BODY SKILLCONSTRUCTION OF BODY SHELLMATERIAL OF BODY SHELLSAFETY FEATURE S AND ITS IMPORTANCEATTACHMENT OF BODY SHELL

VEHICLE

VEHCILE BE DIVIDED IN TO TWO MAJOR COMPARTMENTS

BODY SHELLPERFORMANCE SYSTEM

BODY SHELLBODY SHELL OF AN AUTOMOTIVE VEHICLE IS THE STRUCTURE WHICH PROTECTS :

THE OCCUPENTSANY OTHER PAY LOADTHE PERFORMANCE PARTSOTHER COMPONENTS

LADDER FRAMESo named for its resemblance to a ladder, the ladder frame is the simplest and oldest of all designs. It consists merely of two symmetrical rails, or beams, and cross members connecting them. Originally seen on almost all vehicles

UNI BODY MONOCOQUEMonocoque or uni body construction, in which the "chassis" is part of, and integrated with the metal body. It provides support to all the mechanical components, as well as protection for the vehicle occupants. Although there is no separate complete frame or chassis

SUB FRAME

The sub frame, or stub frame, is a boxed frame section that attaches to a unibody. Seen primarily on the front end of cars, it's also sometimes used in the rear. Both the front and rear are used to attach the suspension to the vehicle and either may contain the engine and transmission

MATERIAL STEEL ALLUMINIUM

POLY URETHENE, PLASTIC, F.R.P.MATERIALCOMPOSITE CARBON

PLASTIC / RUBBERNOICE VIBRATION HARNESS

BODY SEALENTDIAGRAM BODY FILLER

SAFETY FEATURES IN BODY SHELL CRUMPLED ZONEREINSFORCEMENT PANELSREINFORCEMENT BARSSAFETY BARS

BODY SHELL WITH ALL SAFETY FEATURES

COMPLETE BODY SHELLINCLUSIONS OF PANELS LIKE FRONT BONNET, FENDERS, DOORS DICKY LIDS

REPAIRING CATAGORYREPAIRING SIMPLE PANEL AREAREPAIRING PANEL SUPPORTED WITH FRAMEREPAIRING SANDWICH PANELSREPAIRING PANELS SUPPORTED WITH CRUMPLED ZONE AND REINFORCEMENT PANELSREPLACEMENT OF SIMPLE PANEL AND WELDED PANELS

REPAIRING PROCESS & EQUIMMENTS

PANEL BEATING

BASIC BODY REPAIRING TECHNIQUEREQUIRES MOST SKILLS EXPERT KNOWLEDGE REQUIRED TO GET RID OF BUMPS, DENTS AND BREAKAGEUSE OF VARIOUS TECHNIQUES AND TOOLS

PANEL BEATING EQUIPMENTS

HAMMERSDOLLYSPULLERSHACKSAW BRUSHCUTTERSSCRAPERSFILES

GETTING RID OF RUST With rust proofing, one will need to know how and why rust occurs so you can effectively prevent it and get rid of it when it forms on any body part. You will also learn about the many products and techniques that are involved with rust removal and rust inhibiting.

CUTTING & WELDING Welding means using heat to attach two pieces of metal.Heat can be generate , Either gas or electricity. Many Types of welding available in marketGas welding (oxy-acetylene welding), Spot weldingMIG welding TIG welding.

GAS WELDING welding can be done by heating of both panels. Flame is required to heat the panelsFlame can generated by combustion of acetylene with oxygen. welding can be done with or without the use of filler metal.Gas welding is most basic and commenly used method of welding in automotive body reair shop.Gas welding is used to cut the metel as well to joint the matel panels

SAMPLE GAS WELDING

SPOT WELDINGContacting metal surfaces are joined by the heat obtained from resistance to electric current flow. electrodes are required used to joint sandwich panels as well as other body joints.

SAMPLE SPOT WELDING

MIG WELDING(metal inert gas welding) Provides uniform weld bedSemi automatic welding processLong welding can be achieved without intervals Wire is continuously fed from a spool.Argon or helium gas is used to generate heat

TIG WELDING(tungsten inert gas welding)Used to weld thin metalsHigh quality and superior weld can be achievedAn arc is formed between a non consumable tungsten electrode and the metal being welded. Gas is fed through the torch to shield the electrode and molten weld pool.

JACK & PULLER

WITH CAR ALIGNER COMPUTERISED BODY ALIGNMENT SYSTEM By using the specially designated jigs it can simultaneously correct body damage and control realignment by accurate measurement of critical dimensions. The car is then reassembled on the alignment system, thereby ensuring restoration is completed to the original manufacturers specifications and tolerances.

MIRACLE DENT REMOVING SYSTEM

VEHICLE UNDER REPAIR

DEMO SEQUENCEOF REMOVING CRITICAL DENT FROM BODY PANEL

DENT ON VEHICLE

CUTTING BACK BACK PANEL

REPAIR OUTER PANEL FROM BACK

PANEL BEATING WITH DOLLY & FILE

INSPECTION & FINISHING WORK

PULLING & FIXING OF PANELS

INSPECTION & ERROR REMOVING

PREPARATION OF RE JOINTING OF PANEL

RE JOINT PROCESS IS ON

RE JOINT IS ALMOST DONE

PANEL READY FOR PAINT JOB

ACKNOWLEDGEMENTSpecial Thanks to,Insurance Surveyor Association, Surat M/s Weltech Motors, Surat for providing opportunity.Mr. Samir Joshi, Mr. Narendra Panwala, Mr. Vimal Joshi for their valuable guidance in making this presentation.

THANK YOU

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