Table of Contents

Section 1 Introduction to Collision Repair

1 Introduction to Collision Repair 1

2 Safety 7

3 Vehicle Construction 13

4 Fundamentals of Collision Damage 19

5 General-Purpose Tools and Equipment, Service Information 25

6 Fasteners 33

7 Welding and Cutting 39

Section 2 Nonstructural Repairs

8 Nonstructural Repair Tools, Equipment, and Materials 47

9 Nonstructural Panel Repair 55

10 Bolted Nonstructural Part Replacement 63

11 Welded and Bonded Nonstructural Panel Replacement 69

12 Plastic Repair 77

13 Glass 83

Section 3 Structural Repairs

14 Unibody/Frame Straightening Equipment 89

15 Measurements 95

16 Unibody Straightening 101

17 Full-Frame Repair 109

18 Structural Component Replacement 115

Section 4 Mechanical and Electrical Repairs

19 Steering and Suspension 121

20 Electrical System 127

21 Brakes 133

22 Cooling, Heating, and Air Conditioning Systems 139

23 Power Train 145

24 Restraint Systems 151

Section 5 Refinishing

25 Refinishing Tools and Equipment 155

26 Refinish Materials 159

27 Paint Mixing and Reducing 165

28 Spray Technique 171

29 Surface Preparation 177

30 Color Matching 185

31 Paint Application 189

32 Specialty Painting 193

33 Detailing 197

Section 6 Estimating and Certification

34 Estimating 201

35 ASE Certification 205

36 Employment Strategies and Employability Skills 209

Jobs

Job 1 Safety 213

Job 2 Reading a Repair Order and Planning the Repair 217

Job 3 Vehicle Basics 221

Job 4 MIG Welding Basics 227

Job 5 MIG Welding Practice 231

Job 6 Metal Finishing Skills 235

Job 7 Removing and Installing Interior Trim 239

Job 8 Removing and Installing Bolted Panels 243

Job 9 Panel Splicing 249

Job 10 Flexible Plastic Repair 251

Job 11 Measurements 255

Job 12 Removing and Installing Short Arm/Long Arm Suspension Components 261

Job 13 Removing and Installing a MacPherson Strut Assembly 267

Job 14 Removing and Installing a Radiator 271

Job 15 Removing and Installing a Drive Axle 273

Job 16 Electrical Practice 275

Job 17 Masking 279

Job 18 Mixing, Applying, and Sanding Body Filler 283

Job 19 Reducing Paint 287

Job 20 Spray Gun Basics 291

Job 21 Spray Gun Practice 295

Job 22 Spraying Basecoat/Clearcoat Paints 297

Job 23 Preparing for a Clearcoat Blend 303

Job 24 Cleaning a Spray Gun 307

Job 25 Buffing 309

Job 26 Applying Pinstripes 313

Job 27 Preparing a Vehicle for the Customer 317