straightening aluminum program 1 module 3 - straightening aluminum... · and reviewed. if, however,...

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Straightening AluminumProgram 1

Straightening Aluminum Program 1 v.4.1© 2002 Inter-Industry Conference On Auto Collision Repair

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Module 3

Instructor Information

Instructor Manual

MODULE 3–PAINTLESS DENT REPAIR (PDR)

Class0:15

Learning Objectives

The learning objectives for this module include:

identifying where paintless dent repair (PDR) can be used on aluminum panels.

using PDR tools and equipment. taking precautions during the PDR process.

Topic A. Considerations

The learning objectives for this module include:

• identifying where paintless dent repair (PDR) can be used on aluminum panels.

• using PDR tools and equipment.

• taking precautions during the PDR process.

A-1


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Repair Considerations

Some things to consider when doing PDR include:

the number of dents in the panel. access to the backside of the panel being

repaired. the possibility of damage to the finish. removing all of the dents to make an invisible

repair.

Topic A. Considerations (cont’d)

A-2


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Damage To Finish

Applying heat to the damaged area may soften the aluminum and prevent damage to the finish. An infrared (IR) heat lamp or heat gun can be used. Damage to the finish can be the result of prying up too hard on a dent. The result is that the panel will have to be refinished.


A-3

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Damage To The Backside


When PDR is performed, plastic or covered tips should be used to prevent scratches on the inside of the panel. The pick is leveraged against the inner panel so caution should be used so that the inner panel is not damaged. Holes should NOT be drilled in the inner panel to gain access to a dent. This can cause a weakness in the inner structure.

A-4

Damage From Prying

Scratch On Inner Panel

Damage From Prying

Scratch On Inner Panel

Tips should be used on PDR picks to prevent damage to the finish and scratches to the inner panel. Holes should not be drilled into the inner panel to gain access.

Objectives Worksheet


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PDR Tools


Some of the tools needed to perform PDR include:

prys. picks. plastic punches and drifts. These are used to

tap down small high spots. plastic tips. light to illuminate the panel. rings to act as a fulcrum.

A-5


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A-6vVideo: Paintless Dent Repair



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Instructor Manual

Glue-On Dent Removal Tools

Topic B. Glue-On Tools

When using a glue-on dent removal system for PDR, the finish should be an OEM baked finish in sound condition. The reason for this is that the glue may pull the finish away from the metal. This method can also be used for conventional repairs not involving PDR.

B-1

When using a glue-on dent removal system for PDR, the finish should be an OEM baked finish in sound condition.



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Glue-On Dent Removal Tools (cont’d)

Topic B. Glue-On Tools (cont’d)

When using glue-on dent removal tools, a slide hammer or a leverage puller is used to pull out on the low areas. When the repairs are complete, a special release agent is used to remove the attach-ment and the glue from the finish.

B-2

A special release agent is used to remove the attachment and the glue from the finish.



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Glue-On Tools Using A Bridge

Topic B. Glue-On Tools (cont’d)

Glue-on tools can also use a “bridge” assembly that will hold down high areas and pull out the low area. The base or bridge is positioned around the dent on areas that could be high spots. The attachment is threaded and when the lock nut is tightened up, the low spot is lifted while the high spot is pushed down.

B-3

A bridge can also be used to lift low areas and push down on high spots.



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Review #1

Topic C. Review

Technician A says that plastic tipped PDR picks should be used whenever possible.

Technician B says that access holes should be drilled when inserting a PDR pick into a panel.

Who is right?

A. A onlyB. B onlyC. Both A and BD. Neither A nor B

C-1

Technician A says that plastic tipped PDR picks should be used whenever possible.

Technician B says that access holes should be drilled when inserting a PDR pick into a panel.

Who is right?

A. A only

B. B only

C. Both A and B

D. Neither A nor B


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Instructor Manual

Review #2

Topic C. Review (cont’d)

When using glue-on dent removal equipment for PDR, the attachments should be removed with:

A. a hammer and chisel. B. lacquer thinner. C. dye penetrant. D. release agent.

C-2

When using glue-on dent removal equipment for PDR, the attachments should be removed with:

A. a hammer and chisel.

B. lacquer thinner.

C. dye penetrant.

D. release agent.


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Conclusion

Topic D. Conclusion

Topics discussed in this module included:

PDR techniques. PDR considerations. tools used for PDR. glue-on dent removal.

D-1


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Post-Test

Before beginning the post-test, the answer sheets need to be correctly filled out. Any missing informa-tion will delay the issuing of credit for this program. Have the Students clearly fill in their:

SSN/SIN/I-CAR ID number. phone number. name, leaving a space between the last and

first name, and between their first name and middle initial.

the two letter abbreviation for the State or Prov-ince. This should be filled in under CODE.

test version letter (A, B, C, or D) under TEST FORM. The version letter appears in the upper right corner of the Post-Test Question Book-let.

Topic D. Conclusion (cont’d)

It is very important that the Students properly fill out the answer sheet before starting the Post-Test.

Select the graphic text for a larger view of each section of the Scantron form that is required to be filled out by the Students.

Contesting A QuestionAll questions contained in this Post-Test have been carefully developed and reviewed. If, however, a Student feels that a question has multiple answers or is incorrect in any way, they still must answer it with what they feel is the best answer. They can then also darken the letter E on the form for that question and write their concern on the back of the form. This is only to alert staff of a Student’s concern and does not mean the Student is not responsible for answering the question correctly.

This process is to be used in extreme situations where a Student feels strongly that there is a problem with a question and brings it to the atten-tion of the Instructor/Administrator, and should not be announced to the class.

D-2

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The Students also need to clearly write in the:

Instructor’s name on the line appearing after NAME.

post-test booklet number on the line appear-ing after SUBJECT. This number is located on the upper left corner of the question booklet after the words POST-TEST.

date of the class on the line appearing after DATE.

Direct the Students to answer all questions in the question booklet using the appropriate area on the answer sheet. Use a pencil to darken the circle which represents the best answer to the question. There is only one correct answer for each question.

The answer sheet is electronically scanned, so ques-tions will not be scored as correct if they are:

answered with more than one answer. not clearly marked on the answer sheet. mistakenly marked and not completely

erased. completed in ink.

At the completion of the Post-Test, Students are to hand in both the completed answer sheet and the question booklet. Students are not allowed to keep the question booklets! It is the Post-Test administrator’s responsibility to make sure that all test booklets are returned to I-CAR with the answer sheets. Post-Test questions are changed often and printed “on demand”, so there is no advantage to keeping the question booklets.


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Place the Post-Test and the completed answer sheets in the provided envelope and mail them to I-CAR for scoring. Students will be informed of their test results upon scoring of the tests and processing by I-CAR.


straightening aluminum program 1 module 3 - straightening aluminum... · and reviewed. if, however,...

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