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Standard |
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R State
Standard £ Institutionally Developed College: NA |
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ACR 2250 - Unibody Structural Panel Repair and Replacement |
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Course Description 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 |
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Rear Cross Member |
D. Lab |
2 |
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Apron and Rails |
P. Lab/O.B.I. |
3 |
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Trans X Member |
Credit |
3 |
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Rocker |
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W/S Posts |
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Hinge Pillar |
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Center Pillar |
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Floor Pan |
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Spot Weld Removal |
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Panel Sectional Cuts |
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Damaged Panel Removal and Replacement |
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Prerequisite: |
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Corequisite: |
ACR 1000, ACR 1010, ACR 1020, ACR 1060 and ACR 1210 |
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Course
Guide |
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Competency |
After
completing this section, the student will be able to: |
Hours |
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Class |
D. Lab
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P. Lab/ O.B.I. |
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PRIMARY STRUCTURE |
4 |
2
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0 |
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Components |
Identify components on review and quiz sheet. |
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0 |
2
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3 |
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Location |
Locate
components of high strength low alloy steel on illustration chart. |
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Repair, removal, and replacement |
Explain repair or replacement procedures for HSLA structural parts. |
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Remove damaged components and properly align and replace using
preferred methods according to manufacturers' specifications and
recommendations if necessary. |
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Corrosion protection |
Restore corrosion protection. |
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APRON AND RAILS |
0 |
2
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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 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 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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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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Restore corrosion protection. |
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TRANS X MEMBER |
0 |
2
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2 |
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Damage analysis |
Demonstrate 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
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2 |
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Damage analysis |
Examine rocker to determine whether to repair, section or replace
complete panel. |
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Identify rocker as two or three piece design. |
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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. |
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Replace panel by properly aligning and fastening using factory
recommended procedures to include plug welding, butt joint with insert,
intermittent lap weld seams. |
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Corrosion protection |
Restore corrosion protection. |
0 |
1
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3 |
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W/S POST |
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Damage analysis |
Examine pillar to determine whether panel is a two or three piece
design. |
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HINGE PILLAR |
0 |
1
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3 |
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Removal and replacement |
Remove and replace pillar to include removing necessary spot welds and
seam cut as necessary to align and fasten replacement panels. |
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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. |
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CENTER PILLAR |
0 |
2
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3 |
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Removal and replacement |
Explain procedure for removing and replacing center pillar. |
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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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Weld panel using recommended procedures. |
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Corrosion protection |
Restore corrosion protection and finish. |
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FLOOR PAN |
0 |
2
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2 |
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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. |
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Undercoat and finish. |
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SPOT WELD REMOVAL |
2 |
2
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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 saw 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
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4 |
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Damage analysis |
Analyze damaged area on vehicle and determine whether structural
integrity of vehicle would be lessened by sectioning. |
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DAMAGED PANEL REMOVAL AND REPLACEMENT |
1 |
2
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3 |
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Damage analysis |
Make necessary cuts to remove damage. |
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Removal and replacement |
Remove any spot welds and follow manufacturers' recommendations when
working with HSLA panels. |
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Fasten replacement panels and check fit. |
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Corrosion protection |
Restore corrosion protection. |
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Finish repaired panel. |
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Suggested
Resources |
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Media |
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Print |
Duffy, James E. Auto body repair technology (5th
Ed.). (2009). New York: Delmar – Cengage. Duffy, James E. Auto body repair technology (4th
Ed.). (2004). New York: Delmar Learning. |
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AV |
Corrosion protection: CPS01
[CD-ROM]. (2001). Illinois: Inter-Industry Conference on Auto Collision
Repair [Producer and Distributor]. Adhesive bonding: ADH01
[CD-ROM]. (2007). Illinois: Inter-Industry Conference on Auto Collision
Repair [Producer and Distributor]. Welded and adhesively bonded panel
replacement: EXT02 [CD-ROM]. (2002). Illinois:
Inter-Industry Conference on Auto Collision Repair [Producer and
Distributor]. Automotive foams: FOM01
[CD-ROM]. (2005). Illinois: Inter-Industry Conference on Auto Collision
Repair [Producer and Distributor]. Measuring: MEA01
[CD-ROM]. (2001). Illinois: Inter-Industry Conference on Auto Collision
Repair [Producer and Distributor]. Replacing aluminum exterior panels:
PRA01 [CD-ROM]. (2003). Illinois: Inter-Industry Conference on
Auto Collision Repair [Producer and Distributor]. Steel unibody front and rear rails,
floors, and front structure: SPS01 [CD-ROM]. (2001). Illinois:
Inter-Industry Conference on Auto Collision Repair [Producer and
Distributor]. Steel unibody A, B, C. D-pillars, and
rocker panels: SPS02 [CD-ROM]. (2001). Illinois:
Inter-Industry Conference on Auto Collision Repair [Producer and
Distributor]. Structural straightening aluminum:
SSA01 [CD-ROM]. (2003). Illinois: Inter-Industry Conference on
Auto Collision Repair [Producer and Distributor]. Structural straightening steel: SSS01
[CD-ROM]. (2002). Illinois: Inter-Industry Conference on Auto Collision
Repair [Producer and Distributor]. |
Posted:
09/20/09