Basic principles in bodywork processing

This damage
on the
original
vehicle has
to be
repaired!

Student Edition

Which methods
can be used to
repair the
damage?

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

Solution suggestions!
1. ___________________________________________________________
2. ___________________________________________________________
3. ___________________________________________________________
4. ___________________________________________________________
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Tools needed for basic bodywork

repair.

Information!
The activities shown in the following represent a didactically prepared repair
job 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 plastics
processing.

Sample sillboard

The system shown above was developed so that students can carry out
a practical repair themselves.
All of the work shown in the following illustrations can be carried out.
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1. Bodywork processing

(Section repair) What do the pictures show ?

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Picture 1

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Risk of accident:
Use protective
welding equipment .

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17 a

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Risk of accident:
Wear protective goggles, leather gloves and, as
necessary, ear protection. Beware of flying sparks.

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Risk of accident:

and

Make sure that the new

section is securely clamped
when cutting.

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Note:
see item 14

Note:
see item 19

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Caution:
High temperatures will cause

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warping.

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Risk of accident:
Use protective
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Risk of accident:
See item 19

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Risk of accident: See item 19

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2. Work techniques in sheet forming

Drawing out techniques!
Making and fitting the section!

Tin loop, ______________________

The section can

be _____________
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Bumping work

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Depending on the requirements,

the teacher is given a wide range
of possibilities to achieve his
didactic targets.

Tool selection

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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 sheets
As the illustrations for panel beating show, the
same basic frame can be used to carry out
sheet adhesion work using the example of an
adhesion 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 be
carried out here using
commercially available repair
systems.
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 out
in accordance with the repair
guidelines of the manufacturer
(here Fiat Lancia).
TIP! Commercially available repair systems
can also be used here.

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