|
Standard |
Posted:
ACR 125 - Unibody Structural Panel
Repair and Replacement
Provides instruction in attachment methods, proper repair and
replacement of structural panels, dimensional control, areas of high stress
concentration, sectional principles, and crush zones. Selection and preparation of
recycled parts will be emphasized. Topics include: primary structure, rear
cross member, apron and rails, trans X member, rocker, w/s posts, hinge pillar,
center pillar, floor pan, spot weld removal, panel sectional cuts, and damaged
panel removal and replacement.
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Competency Areas |
Hours
|
|
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Primary
Structure |
Class |
1 |
|
Rear
Cross Member |
D. Lab |
2 |
|
Apron and
Rails |
P.
Lab/O.B.I. |
3 |
|
Trans X
Member |
Credit |
3 |
|
Rocker |
|
|
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W/S Posts |
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|
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Hinge
Pillar |
|
|
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Center
Pillar |
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Floor Pan |
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|
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Spot Weld
Removal |
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|
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Panel
Sectional Cuts |
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Damaged
Panel Removal and Replacement |
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Prerequisite/Corequisite: |
ACR 122,
ACR 124 |
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Course Guide |
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Competency |
After completing this section,
the student will: |
Hours |
||
|
Class |
D.Lab
|
P.Lab/ O.B.I. |
||
|
PRIMARY STRUCTURE |
4 |
2
|
0 |
|
|
Components |
Identify
components on review and quiz sheet. |
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REAR CROSS MEMBER
|
0 |
2
|
3 |
|
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Location |
|
|
|
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Repair,
removal, and replacement |
Explain
repair or replacement procedures for HSLA structural parts. Remove damaged
components and properly align and replace using preferred methods according
to manufacturers' specifications and recommendations if necessary. |
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|
|
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Corrosion
protection |
Restore
corrosion protection. |
|
|
|
APRON AND RAILS
|
0 |
2
|
2 |
|
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Damage
analysis |
Analyze
damage to determine whether to repair or replace damaged sections. |
|
|
|
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Risk
zones |
Identify
and demonstrate a knowledge of "risk"
zones. |
|
|
|
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Removal
and replacement |
Determine
if rails are closed section or open "hat" channel. Explain
replacement procedure for each. |
|
|
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Procedures |
Explain
procedure for removing high strength steel panels when replacement is
necessary. |
|
|
|
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Stress
relieving |
Demonstrate
a knowledge of stress relieving secondary damage in
adjacent panels. |
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Spot weld
removal |
Demonstrate
proper method and equipment when removing spot welds and seams on damaged
panels. |
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|
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Removal
and replacement |
Remove
damaged panels, measure and align replacement panels using necessary
equipment, properly weld replacement panels using manufacturers' recommended
procedures properly and safely. |
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|
|
|
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Restore
corrosion protection. |
|
|
|
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TRANS
X MEMBER |
0 |
2
|
2 |
|
|
Damage
analysis |
Demonstrate
a knowledge of X member by explaining repair or
replacement using manufacturers' recommended procedures. |
|
|
|
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Repair,
removal, and replacement |
Repair or
replace X member using safe and proper manufacturers' recommended techniques. |
|
|
|
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Restore
corrosion protection. |
|
|
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ROCKER
|
0 |
2
|
2 |
|
|
Damage
analysis |
Examine
rocker to determine whether to repair, section or replace complete panel. |
|
|
|
|
|
Identify
rocker as two or three piece design. |
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|
|
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Repair,
removal, and replacement |
Remove
damaged section using safe and proper manufacturers' recommended techniques
to include removing spot welds, cutting around A & B pillars as necessary
sectioning if needed as necessary. |
|
|
|
|
|
Replace
panel by properly aligning and fastening use factory recommended procedures
to include plug welding, butt joint with insert, intermittent lap weld seams. |
|
|
|
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Corrosion
protection |
Restore
corrosion protection. |
|
|
|
W/S POST
|
0 |
1
|
3 |
|
|
Damage
analysis |
Examine
pillar to determine whether panel is a two or three piece design. |
|
|
|
HINGE PILLAR
|
0 |
1
|
3 |
|
|
Removal
and replacement |
Remove
and replace pillar to include removing necessary spot welds and seam cut as
necessary to align and fasten replacement panels. |
|
|
|
|
|
Check fit
adjacent part before welding. |
|
|
|
|
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Weld
using recommended techniques. |
|
|
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Corrosion
protection |
Restore
corrosion protection and finish. |
|
|
|
CENTER PILLAR
|
0 |
2
|
3 |
|
|
Removal
and replacement |
Explain
procedure for removing and replacing center pillar. |
|
|
|
|
|
Remove
center pillar by properly removing all spot welds and seam welds following
manufacturers' recommendations. |
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Fit
replacement panel and seam with clamps, screws, rivets, etc. |
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Check fit
of adjacent panels. |
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|
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Weld
panel using recommended procedures. |
|
|
|
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Corrosion
protection |
Restore
corrosion protection and finish. |
|
|
|
FLOOR PAN
|
0 |
2
|
2 |
|
|
Damage
analysis |
Analyze
damaged vehicle to determine best area to section floor pan. |
|
|
|
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Removal
and replacement |
Make
necessary cuts to allow for overlap of replacement panels. |
|
|
|
|
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Weld
panel according to manufacturers' recommendations to include plug weld
overlap from top. |
|
|
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Corrosion
protection |
Restore
corrosion protection and seam sealer to weld joint area. |
|
|
|
|
|
Undercoat
and finish. |
|
|
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SPOT
WELD REMOVAL |
2 |
2
|
3 |
|
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Methods |
Explain
various methods to remove spot welds and how each is used to include spot
cutter (drill type), spot cutter (hole slow type). |
|
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Explain
how to locate spot welds and demonstrate on spot welded panel. |
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Remove
spot welds using above methods on panel according to recommended procedures. |
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PANEL SECTIONAL CUTS
|
3 |
0
|
4 |
|
|
Damage
analysis |
Analyze
damaged area on vehicle and determine whether structural integrity of vehicle
would be lessened by sectioning. |
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