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Intro To Tools, Equipment, And Attachment Methods - Part 1 Textbook Version: 14.2 © 2012 - 2013 Inter-Industry Conference On Auto Collision Repair

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Intro�To�Tools,Equipment,�And

AttachmentMethods�-�Part�1

Textbo

ok

Version:�14.2

©�2012�-�2013�Inter-Industry�Conference�On�Auto�Collision�Repair

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Intro�To�Tools,�Equipment,�And�Attachment�Methods�-�Part�1Textbook

Table�of�Contents 3

Contents

Introduction..............................................................................................................................7Obligations�To�The�Customer�And�Liability.......................................................................... 7

Intro�To�Tools,�Equipment,�And�Attachment�Methods�-�Part�1.................................................11Basic�Tools� -�Part�1.............................................................................................................11Basic�Tools� -�Part�2.............................................................................................................14Mechanical�Fastening......................................................................................................... 19Glass�And�Trim...................................................................................................................22Estimating�Tools�And�Processes.......................................................................................... 24

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Introduction

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IntroductionTextbook

Intro�To�Tools,�Equipment,�And�Attachment�Methods�-�Part�1 7

Obligations�To�The�Customer�And�Liability

The�Collision�Repair�Industry�hasan�obligation�to�correctly�repair�thecustomer’s�vehicle.�Collision�repairs�mustbe�performed�using:

• recommended�or�testedprocedures�from�vehicle�makers,I-CAR,�and�other�research�andtesting�organizations.

• quality�replacement�parts�andmaterials.

• repair�processes�and�parts�aswritten�and�agreed�upon�in�therepair�order.

• If�items�on�the�repair�agreementare�not�consistent�with�the�repairorder,�it�can�be�considered�fraud.

Performing�proper�collision�repairsrequires�using�parts�and�procedures�thatkeep�remaining�warranties�intact.Collision�repairs�must�restore:

• safety.• structural�integrity.• durability.• performance.• fit.

• finish.

Throughout�the�damage�analysis�andrepair�process�the�repairer�and�insurermust:�communicate�with�each�other.

• maintain�constant�communicationwith�the�customer.

• be�in�agreement�with�each�otherand�the�customer�on�how�repairswill�be�performed.

• inform�the�customer�of�anychanges�in�the�repair�plan�fromthe�original�repair�agreement,�andexplain�the�changes�and�why�theyhave�to�be�made.

To�reduce�liability:

• make�sure�that�all�repairs�areperformed�thoroughly,�correctlyand�as�listed�in�damage�report.

• follow�proper�procedures.• use�quality�replacement�parts�and

materials.• have�documentation�of�required

repairs�with�detailed�recordkeeping�available�for�customers.

IntroductionTextbook

Intro�To�Tools,�Equipment,�And�Attachment�Methods�-�Part�1 8

Technicians�are�considered�theexperts�and�are�expected�to�beknowledgeable�on�how�to�performa�quality�repair.

Keeping�thorough�records�includes�morethan�recording�the�date,�mileage,�andpre-existing�damage.�Record�keepingalso�includes:�making�sure�all�notes�arelegible.

• verifying�the�repairs�that�weremade�or�not�made.

• having�the�customer�sign�awaiver�for�repairs�that�they�donot�want�performed.�Repairersmust�determine�their�liability�onnot�repairing�safety�systems�suchas�restraint�and�anti-lock�brakesystems.

• keeping�computer�printouts�orworksheets�on�file�showing�wheelalignment�readings�or�vehicledimensions�before�and�afterrepairs.

• keeping�scan�tool�printouts�andrecords�of�computer�codes�forairbag,�anti-lock�brake,�emission,and�powertrain�control�module(PCM)�systems.�attaching�the�OEMor�other�tested�procedure�printoutto�the�vehicle�repair�order.

• keeping�receipts�for�all�subletwork�performed.

Liability�insurance�that�covers�the�repairfacility�may�not�always�cover�all�damages.For�example:

• the�policy�may�not�coverfaulty�repairs,�leaving�liabilityresponsibility�completely�on�thefacility.

• a�shop�owner�may�find�that�repairfacility�liability�coverage�may�notcover�the�full�amount�awarded�ina�lawsuit.�The�shop�owner�wouldhave�to�pay�the�difference.

Intro�To�Tools,Equipment,�And

Attachment�Methods-�Part�1

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Intro�To�Tools,�Equipment,�And�Attachment�Methods�-�Part�1Textbook

Intro�To�Tools,�Equipment,�And�Attachment�Methods�-�Part�1 11

Basic�Tools�-�Part�1

Learning�objectives�for�this�moduleinclude:

• identifying�the�uses�for�a�hammerand�dolly.

• explaining�the�purpose�of�paintlessdent�repair�tools.

• explaining�the�different�types�ofdent�pulling�equipment�and�whatfiles�are�used�for.

• explaining�the�differences�betweena�grinding�wheel�and�a�cut-offwheel.

• describing�the�two�common�sawsused�in�a�collision�repair�facility.

Video:�Hammer�And�Dollies

Hammer�And�DolliesHammers�and�dollies�used�in�collisionrepair�are�available�in�different�shapes�andsizes.�Various�ones�may�be�suitable�fordifferent�types�of�repairs.

A�hammer�and�dolly�can�be�used�tostraighten�dents�or�flanges,�such�as�this.

Some�picks�are�used�to�move�metal�to�an�initialposition.

Picks�are�typically�used�after�initialstraightening�of�a�part�has�beencompleted.

Picks,�though�they�may�resemble�apaintless�dent�repair�tool,�are�not�usedfor�the�same�function.�A�paintless�dentrepair�tool�is�used�to�move�metal�in�away�that�does�not�disturb�the�topcoat.�Apick�is�used�to�move�metal�that�may�berefinished.

Video:�Drills�And�Drill�Bits

Drills�And�Drill�BitsDrills�used�in�a�collision�repair�facilitymay�be�electric,�pneumatic,�or�battery-operated.�These�tools�are�used�to�makeholes�as�well�as�remove�spot�welds.

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Intro�To�Tools,�Equipment,�And�Attachment�Methods�-�Part�1 12

There�are�different�types�of�drill�bits�thatare�used�depending�on�the�material�beingdrilled.�Gold�drill�bits�are�typically�usedfor�hardened�steel,�while�these�(spot�weld)drill�bits�are�designed�to�remove�spotwelds.

Wire�brushes�may�have�carbon�or�stainless�steelbristles.

Wire�brushes�are�typically�used�forremoving�rust�or�heavy�coatings�from�steelor�cast�iron�parts.�These�brushes�may�alsobe�used�for�cleaning�steel�or�aluminumbefore�welding.

Video:�Air�Chisel

Air�ChiselThis�is�a�pneumatic�chisel,�also�referredto�as�an�air�chisel.�Depending�on�the�bitbeing�used,�it�can�be�used�to�break�apart

spot�welds,�as�well�as�cut�apart�sheetmetal.

Video:�Paintless�Dent�Repair�Tools

Paintless�Dent�Repair�ToolsPaintless�dent�repair�tools,�or�PDR�tools,are�designed�to�reach�into�concealedlocations�and�remove�dents�from�thebackside�of�a�panel.�These�tools�canremove�some�cosmetic�damage�withoutrequiring�refinishing.

Video:�Dent-Pulling�Equipment

Dent-Pulling�EquipmentTwo�general�types�of�dent�removal�toolsinclude�systems�that�use�glue-on�or�weld-on�attachments.

The�glue-on�attachments�are�typicallyused�for�paintless�dent�repair,�such�as�haildamage.�Once�the�attachment�is�glued�on

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Intro�To�Tools,�Equipment,�And�Attachment�Methods�-�Part�1 13

to�the�center�of�the�dent,�a�slide�hammeris�used�to�remove�the�dent�with�slightpressure,�slowly�removing�the�dent.

The�weld-on�attachments�need�bare�metaland�are�used�for�larger�dents.

Files�may�be�flat�or�rounded.

Files�are�generally�used�for�initial�shapingor�removal�of�large�amounts�of�body�filler.

Cutoff�wheels�may�have�a�maximum�RPM�rating.

Cutoff�wheels�are�used�to�cut�metal.Cutoff�wheels�may�look�similar�to�agrinding�wheel,�however,�cutoff�wheelsare�generally�smaller�and�thinner.

Electric�grinders�work�well�for�grinding�welds�(left).Some�grinders�will�have�many�different�attachments(right).

Grinders�may�be�electric�or�pneumatic.Typically,�the�pneumatic�grinders�arecalled�90°�angle�grinders�and�are�used�forremoving�coatings�or�dressing�welds.

Electric�grinders�are�commonly�usedfor�cutting�or�heavy�grinding�on�vehicleframes�or�welds.

Video:�Saws

SawsThere�are�two�types�of�saws�typically�usedin�a�collision�repair�facility,�electric�andpneumatic.

Intro�To�Tools,�Equipment,�And�Attachment�Methods�-�Part�1Textbook

Intro�To�Tools,�Equipment,�And�Attachment�Methods�-�Part�1 14

Electric�saws�are�mostly�used�whencutting�heavyweight�parts�like�frames�andthick�metal.

Pneumatic�saws�are�used�for�cutting�lightgauge�metal�or�when�precision�cuts�arenecessary.

Any�type�of�tape�measure�can�be�used�as�long�as�itmeasures�in�metric.

Tape�measures�are�often�used�in�acollision�repair�facility�to�measurevehicle�dimensions.�While�they�may�bestandard�measurements,�most�are�metricsince�body�measurements�are�generallyprovided�in�metric.

Topics�discussed�in�this�moduleincluded:

• the�uses�for�a�hammer�and�dolly.• the�purpose�of�paintless�dent

repair�tools.�different�types�of�dentpulling�equipment�and�what�filesare�used�for.

• the�differences�between�a�grindingwheel�and�a�cutoff�wheel.

• the�two�common�saws�used�in�acollision�repair�facility.

Basic�Tools�-�Part�2

Learning�objectives�for�this�moduleinclude:

• identifying�the�uses�of�a�mixingboard�and�spreader.

• explaining�the�different�uses�forsanding�tools�and�scrapers.

• describing�the�different�types�ofpliers�and�their�uses.

• describing�the�use�of�differenttypes�of�wrenches.

• explaining�the�various�types�ofsockets�and�screwdrivers.

Heat�guns�may�look�different,�but�they�serve�thesame�purpose.

Heat�guns�resemble�a�personal�hair�dryer.A�heat�gun:

• has�settings�to�change�the�heatoutput.

• is�used�to�remove�emblems�orsoften�adhesive�for�part�removal.

Intro�To�Tools,�Equipment,�And�Attachment�Methods�-�Part�1Textbook

Intro�To�Tools,�Equipment,�And�Attachment�Methods�-�Part�1 15

Wax-covered�sheets�of�paper�are�used�for�mixingbody�filler.

Mixing�boards�are�used�to�mix�bodyfiller�or�other�two-part�materials�oncoated�paper.�After�the�body�filler�hasbeen�mixed�and�applied,�the�remainingmaterial�left�on�the�coated�paper�can�betorn�off�and�discarded.

Material�spreaders�are�plastic�and�areused�for�applying�body-filler�material.

Video:�Sanding�Tools

Sanding�ToolsSome�common�sanding�tools�used�in�acollision�repair�facility�include�a�dual-action�sander,�more�commonly�referredto�as�a�DA,�a�straight�line�air�sander,�andvarious�sanding�blocks.

We've�placed�tape�on�the�bottom�pad�ofthis�dual-action�sander�to�show�you�thedifferent�circular�and�orbital�motions�ithas.�As�you�can�see,�the�pad�spins�in�acircular�motion,�but�when�I�put�my�handon�it�you�can�see�that�it�also�rotates�inan�orbital�motion.�This�gives�us�the�dual-action�phase�of�the�sander.

Straight�line�air�sanders�are�used�on�largeareas�of�body�filler�that�require�the�surfaceto�remain�flat.�Depending�on�the�sandingoperation,�various�shaped�blocks�may�beused.�They�are�also�available�in�variouslengths.�Some�blocks�may�be�flexible,while�others�are�rigid.

Blow�guns�may�have�different�types�of�tip�adapters.

Blow�guns�are�used�to�force�compressedair�at�a�controlled�pressure�to�a�surfaceto�remove�debris.�Using�compressed�airhelps�to�reduce�the�chance�of�scratchingthe�surface�or�embedding�contaminantsinto�a�finish.

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Intro�To�Tools,�Equipment,�And�Attachment�Methods�-�Part�1 16

Some�scrapers�are�used�to�remove�heavyweightcoatings.

Scrapers�are�generally�used�to�removethick�coatings�like�undercoating�or�tar.Scrapers�are�also�used�with�chemicalstrippers�for�removing�coatings�from�apart.

Another�use�for�some�types�of�scrapersis�to�remove�vehicle�moldings�and�trim.Sometimes�this�can�be�done�withoutdamaging�the�painted�surface�or�thetrim.

Allen�wrenches�may�be�bent�at�a�90°.

An�Allen�wrench�is�a�hexagonal�(six-sided)�tool�used�to�turn�screws�withhexagonal�heads.

Some�wrenches�may�have�an�open�end.

Wrenches�are�hand�tools�used�forinstalling�or�removing�bolts�and�nuts.There�are�different�shapes,�lengths,�andtypes�of�wrenches,�but�their�purpose�is�thesame.

Video:�Impact�Wrenches

Impact�WrenchesImpact�wrenches�are�used�to�quicklyremove�and�install�fasteners,�such�as�lugnuts,�or�any�other�fastener�on�the�vehicle.

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Intro�To�Tools,�Equipment,�And�Attachment�Methods�-�Part�1 17

Video:�Pliers

PliersThere�are�a�variety�of�pliers�used�in�acollision�repair�facility.�These�include�sidecutters,�which�can�be�used�for�cuttingwire.�Vise-grips,�such�as�these,�can�beused�to�clamp�a�part�tightly.�Needle-nosepliers,�such�as�these,�are�good�for�gettinginto�tight�spaces.

Another�type�of�vise-grip�is�a�duckbill,which�is�also�used�to�firmly�hold�parts.Flat-nose�pliers�are�used�to�grip�partsmanually.

This�pair�of�pliers�is�used�for�removinginsulation�from�wires.�After�the�insulationis�removed,�the�tool�is�also�used�to�crimpon�wire�connectors,�such�as�this.

Metal�bristles�are�used�for�cleaning�corrosion�fromthe�battery�lead.

Battery�cleaning�tools�consist�of�a:

• dedicated�brush�for�cleaning�acidand�corrosion�from�the�surface�ofthe�battery.

• sharp�edge�for�stripping�a�smalllayer�of�lead�from�the�battery�postsand�connectors�to�help�ensure�asound�connection.

Some�pick-up�tools�may�be�flexible�or�extendable.

Magnetic�pick-up�tools�are�used�forretrieving�a�variety�of�steel�items�that�canfall�in�hard-to-reach�places.

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Intro�To�Tools,�Equipment,�And�Attachment�Methods�-�Part�1 18

Awls�with�different�style�ends�can�access�hard-to-reach�areas.

Awls�are�used�for�scratching�or�scribingcut�lines�on�metal�parts.

This�tire�pressure�gauge�is�also�used�to�inflate�a�tire.

Tire�pressure�gauges�are�used�to�determinethe�amount�of�air�pressure�that�is�in�atire.�Tire�pressure�gauges�may�also�have�adigital�display.

Screwdrivers�are�different�lengths.

Screwdrivers�used�in�a�collision�repairfacility�have�different�designs.�Somescrewdriver�types�include�flat�blade,Phillips,�and�Torx.

These�types�of�screwdrivers�are�usedfor�installing�or�removing�threadedfasteners.

Ratchets�and�sockets�may�be�a�variety�of�differentsizes.

Ratchets�are�hand�operated�or�pneumaticand�use�different�sized�sockets.�Specialsockets�are�designed�for�use�with�animpact,�and�some�sockets�are�designed�tonot�be�used�with�an�impact.

Topics�discussed�in�this�moduleincluded:

• the�uses�of�a�mixing�board�andspreader.

• the�different�uses�for�sanding�toolsand�scrapers.

• the�different�types�of�pliers�andtheir�uses.�the�use�of�differenttypes�of�wrenches.

• the�various�types�of�sockets�andscrewdrivers.

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Intro�To�Tools,�Equipment,�And�Attachment�Methods�-�Part�1 19

Mechanical�Fastening

Learning�objectives�for�this�moduleinclude:

• identifying�some�of�the�bolts,screws,�rivets,�clips,�clinches,�andhem�flanges�used�for�automotiveattachment�applications.

• explaining�characteristics�of�someof�these�mechanical�fasteners�andinstallation�methods.

• explaining�one-time�useconsiderations�for�some�of�thesemechanical�fasteners.

Video:�Bolts�And�Nuts

Bolts�And�NutsBolts�are�used�in�some�vehicleattachments.�They�have�a�head�and�athreaded�shaft.�Bolts�are�available�withdifferent�head�types,�thread�types,�andstrengths.

Bolts�have�a�grade�or�class�number�foreach�type,�the�higher�the�number,�thestronger�the�bolt.

Bolts�may�be�used�with�a�nut.�The�nut�andthread�types�should�match�that�of�the�bolt.The�nut�is�then�threaded�onto�the�boltto�a�recommended�specification.�This�isreferred�to�as�the�torque�specification.

Nuts�are�available�in�various�types�andstrengths.�The�same�grade�or�class�numbershould�match�that�of�the�bolt.

Video:�Screws

ScrewsSome�parts�may�be�attached�with�a�screw.A�screw�consists�of�a�head�and�a�threadedshaft.�There�are�various�styles�that�comewith�different�head�types,�and�strengths.

Screws�are�typically�installed�into�athreaded�hole�without�the�use�of�a�nut.However,�some�screws�do�use�a�nut.

One�type�of�screw�is�a�sheet�metal�screw.When�installing�the�sheet�metal�screw�atapped�hole�is�not�required,�the�hardenedthreads�of�the�screw�cut�threads�into�thesurface.

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Intro�To�Tools,�Equipment,�And�Attachment�Methods�-�Part�1 20

This�is�a�machine�screw.�They�aretypically�manufactured�with�a�roundhead,�and�installed�using�a�nut.

This�is�a�cap�screw.�They�are�typicallymanufactured�with�a�flat�head,�andinstalled�with�or�without�a�nut.

Video:�One-Time�Use�Considerations

One-Time�ConsiderationsSome�mechanical�fasteners�may�beconsidered�one-time�use.�One-time�usefasteners�are�those�that�the�vehicle�makerdoes�not�recommend�reusing�once�theyhave�been�loosened�or�removed.�Onetype�of�these�fasteners�is�this�suspensionbolt.

Additionally,�a�fastener�may�be�consideredone-time�use�because�of�a�special�coating.Some�bolts�have�special�coatings�to�helpprevent�corrosion,�and�this�coating�istypically�damaged�during�removal.

Video:�Additional�Considerations

Additional�ConsiderationsSome�attachments�methods�involve�theuse�of�other�hardware,�such�as�washersand�pins.

Various�materials�and�types�of�washersare�used.�They�provide�a�barrier�betweenthe�fastener�head�or�nut�and�the�panelsurface.�Washers�are�used�for�protectionand�prevention.�For�example,�a�lockingwasher�prevents�the�loosening�of�afastener.

Various�materials�and�types�of�pins�maybe�used�to�link�or�hold�parts�together.�Oneexample�is�a�cotter�pin,�which�is�used�formechanical�part�attachments.

Video:�Rivets

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Intro�To�Tools,�Equipment,�And�Attachment�Methods�-�Part�1 21

RivetsThere�are�several�different�styles�of�rivetsused�for�automotive�attachment�methods,made�from�various�materials.

To�install�some�rivets,�a�hole�must�bepre-drilled�in�the�panel.�The�rivet�isthen�installed�using�a�rivet�gun.�Thereare�several�different�styles�of�rivet�guns,including�manual,�pneumatic,�andelectric.

One�type�of�rivet�is�the�self-piercing�rivetor�SPR.�SPRs�pierce�through�the�piecesbeing�joined�and�expand�through�theinner�panel�into�the�backside�withoutbreaking�through.�No�pre-drilled�hole�isneeded�for�installing�an�SPR.

These�are�solid�rivets.�They�have�a�solidshank,�and�require�a�pre-drilled�hole�forinstallation.

These�are�blind�rivets.�Blind�rivets�havetwo�sections,�the�rivet�and�the�mandrel.The�rivet�section�is�the�part�that�locks�tothe�panel�surface.�The�mandrel�section�isthe�part�that�is�installed�into�a�rivet�gunand�disposed�of�after�the�rivet�has�beeninstalled.�For�some,�the�rivet�section�maybe�one�material�while�the�mandrel�is�asecond�material.�Some�blind�rivets�mayalso�be�plastic.

Rivets�are�a�one-time�use�fastener.�Theyare�typically�damaged�during�removal.

Video:�Clips

ClipsClips�are�another�type�of�mechanicalfastener�used�for�automotive�attachments.There�are�various�styles�and�materials�ofclips�used.�Some�include�plastic�push-inclips,�and�spring�clips.

A�plastic�clip�with�a�push-in�pin�is�anothertype�of�clip�found�on�vehicles.�These�aredesigned�to�typically�be�reused.

Some�type�of�clips�may�be�designedfor�one-time�use,�or�be�destroyedduring�removal.�Removal�methods�varyaccording�to�the�type�of�clip.

One�example�where�clips�are�used�is�onbodyside�moldings.�With�these�parts,�clipscan�be�either�attached�to�the�molding�orthe�panel.

Many�trim�panels�use�hidden�clips�thatare�pressure-fit�into�holes�to�provideattachment.

There�are�various�types�of�clip�removaltools�available.�Using�an�appropriate

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Intro�To�Tools,�Equipment,�And�Attachment�Methods�-�Part�1 22

tool�may�help�to�remove�the�clip�withoutbreaking�it.

Video:�Clinches�And�Hem�Flanges

Clinches�And�Hem�FlangesClinches�and�hem�flanges�may�also�beused�for�attaching�panels�or�pieces�ofpanels.

A�clinch�is�a�vehicle-maker�joiningmethod�that�uses�a�combination�ofcompression�and�punching.�This�processuses�the�panel�as�its�own�fastener�andthe�installation�process�does�not�requiremaking�a�hole�in�the�panel.�A�clinchis�formed�by�compressing�two�partsbetween�two�dies�to�form�an�interlockingconnection.

A�hem�flange�is�formed�when�the�panelis�attached�to�another�panel�by�crimpingthe�flange�of�one�part�around�the�other.For�example,�most�door�skins�are�attachedto�the�door�shell�using�a�hem�flange�inconjunction�with�welds�and�adhesives.

Topics�discussed�in�this�moduleincluded:

• identification�of�some�bolts,screws,�rivets,�clips,�clinches,�andhem�flanges�used�for�automotiveattachment�applications.

• characteristics�of�some�of�thesemechanical�fasteners�andinstallation�methods.

• one-time�use�considerationsfor�some�of�these�mechanicalfasteners.

Glass�And�Trim

Learning�objectives�for�this�moduleinclude:

• identifying�the�different�types�ofcutting�knives.

• explaining�why�suction�cups�areused�for�installing�glass.

• explaining�the�different�types�ofadhesive�applicator�guns.

Some�power�knives�are�operated�by�compressed�air.

Some�of�the�cutting�tools�used�forremoving�trim�or�stationary�glass�may�beelectric�or�pneumatic�to�help�make�partremoval�easier.

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A�cold�knife�is�typically�pulled�through�the�adhesive(left).�Some�wire�cutting�tools�are�manually�pulledthrough�the�adhesive�(right).

Two�common�glass�cutout�tools�include:

• a�cold�knife,�which�has�an�L-shaped�blade,�a�handgrip,�and�anattached�pull�handle.�This�type�ofknife�has�different�length�blades.

• a�wire�tool,�which�is�a�piece�ofthin-gauge�wire�attached�to�twohandles.�A�wire�tool�may�also�beused�for�removing�moldings.

Suction�cups�are�used�to�lift�glass.

To�help�the�technician�remove�and�installstationary�glass,�suction�cups�are�usedto�pick�up�and�move�the�glass�withouttouching�the�edges.

This�is�one�style�of�a�pneumatic�adhesive�gun.

Windshield�urethane�adhesive�is�avery�thick�material�that�can�be�hard�tomanually�dispense.�There�are�differenttypes�of�applicator�guns.�These�guns�maybe�manual,�pneumatic,�or�electric.

Removal�tools�may�have�unique�shapes.

Door�trim�removal�tools�are�made�indifferent�shapes�to�reach�under�door�trimpanels�to�release�clips.�Some�of�thesetools�look�like�a�pliers�that�pry�apart�whenthey�are�squeezed.�Others�are�generally�aplastic�or�metal�pry�bar-type�tool�used�forremoving�trim�and�clips.

Topics�discussed�in�this�moduleincluded:

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• the�different�types�of�cuttingknives.

• why�suction�cups�are�used�whenworking�with�glass.

• the�different�types�of�adhesiveapplicator�guns.

Estimating�Tools�And�Processes

Learning�objectives�for�this�moduleinclude:

• explaining�why�damage�reportsare�written.

• identifying�when,�where,�and�bywhom�damage�reports�are�written.

• explaining�some�of�the�processesthat�are�done�when�writing�adamage�report.

• identifying�information�sourcesthat�may�be�required�or�helpfulwhen�writing�a�damage�report.

This�is�an�example�of�a�completed�damage�report.

The�functions�of�a�damage�reportinclude:

• keeping�a�record�of�the�estimatedrepair�costs.

• describing�the�work�to�be�donewhen�repairing�a�vehicle.

• helping�to�minimizemisunderstanding�between�therepairer,�insurer,�and�vehicleowner.

• keeping�a�record�of�informationthat�may�be�needed�later�forordering�parts,�making�the�repairsto�a�vehicle,�and�invoicing�therepairs�when�completed.

• documenting�authorizationto�begin�work�on�a�vehicle�asdescribed.

Names�For�Damage�Reports�Other�namesthat�may�be�used�for�damage�reportsinclude:

• repair�estimate.• damage�appraisal.

A�drive-in�claims�service�may�be�an�option�forvehicles�with�light�damage.

Damage�reports:

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• are�written�by�an�auto�physicaldamage�appraiser�or�a�collisionrepair�facility�estimator.

• may�require�an�inspection�of�thedamaged�vehicle.

• may�be�written�anywhere�avehicle�is�located.�Locations�mayinclude�a�collision�repair�facility,a�drive-through�claims�service,�orinsurance�company�location.�Adamage�report�may�also�be�writtenat�the�vehicle�owner's�residence�orplace�of�employment.

Video:�Estimating�Guides

Estimating�GuidesEstimating�guides�are�used�to�look�up�partnumbers,�prices,�and�labor�units�usedfor�replacing�and�refinishing�parts.�Theseestimating�guides�are�available,�eitherelectronically�or�in�print�format.

The�front�section�of�this�printed�estimatingguide�contains�reference�information,such�as�definitions�for�common�terms,�andthe�procedure�pages.

The�majority�of�the�estimating�guidecontains�information�on�most�of�theavailable�replacement�parts�for�a�vehicle.The�parts�are�listed�in�order�from�the�frontof�the�vehicle�to�the�rear.�This�makesit�easier�to�locate�specific�parts�in�theestimating�guide.�For�example,�we�knowwe�can�page�through�to�the�rear�section�ifwe�need�to�look�up�information�on�a�rearbumper�cover.

Illustrations�are�used�represent�the�variousreplacement�parts�and�are�identified�bynumbers.�These�numbers�can�be�used�toidentify�the�part�name,�the�cost�of�the�part,and�the�part�number.

Part�assemblies�are�identified�with�a�boxand�a�number.�This�example�shows�theseparts�can�be�purchased�separately�or�as�acomplete�assembly.

You�can�download�sample�pages�froma�printed�estimating�guide�from�the�linkbelow.

Video:�Computer-Generated�DamageReports

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Computer-Generated�Damage�ReportsMost�damage�reports�are�created�using�anelectronic�estimating�system,�such�as�thissystem.�Here�we�can�add�a�damaged�partto�the�damage�report�by�clicking�on�thepart�in�the�illustration,�or�from�a�list,�suchas�shown�here�on�the�left.

The�estimating�system�automaticallyenters�part�prices�and�does�the�mathnecessary�for�cost�estimating,�such�asincluding�the�part�price,�labor�time�forreplacing�the�part,�and�the�labor�time�andthe�total�cost�for�refinishing�the�part.

Damaged�parts�are�entered�into�thesystem�while�the�vehicle�is�beinginspected,�using�computers�such�as�this,or�done�at�a�later�time�based�off�of�hand-written�notes�by�the�estimator�or�damageappraiser.

When�the�damage�report�is�complete,�itcan�be�printed�or�emailed�in�an�electronicversion.

A�digital�image�is�being�taken�of�the�damage�to�thefront�end�of�this�vehicle.

During�the�damage�report�writing�process,digital�photos�of�the�collision-related

damage�are�taken.�The�digital�photosare�attached�to�a�damage�report.�Thismay�allow�the�damage�appraiser�to�verifydamage�to�the�vehicle�on�a�computerwithout�having�to�visit�the�repair�facility.Photos�of�pre-existing�damage�may�alsobe�taken�to�upsell�additional�repairs�or�fordocumentation.

Digital�photos�may�also�be�added�to�adamage�report�when�additional�damageis�found�during�the�repair�process.�Again,this�allows�the�damage�appraiser�to�verifythe�damage�on�a�computer�rather�thanmaking�a�trip�to�the�repair�facility.

The�customer�is�discussing�details�about�the�collisionwith�the�damage�appraiser�before�the�damage�reportis�written.

A�customer�consultation�is�done�beforeor�during�the�inspection�process.�Acustomer�consultation�may�provideinformation�about�the�vehicle�andcollision.�Information�about�the�collisionobtained�during�a�customer�consultationmay�include:

• the�speed�and�direction�of�theimpact.

• the�road�conditions�at�the�time�ofthe�collision.

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• other�vehicles�or�objects�involvedwith�the�collision.

• whether�or�not�the�vehicle�wasdrivable�after�the�collision.

• which�seat�belts�were�in�useduring�the�collision.�Some�vehiclemakers�recommend�replacing�seatbelts�that�were�in�use�during�acollision.

The�damage�appraiser�is�pointing�out�a�narrow�door-to-quarter�panel�gap�on�one�side�and�a�dent�over�therear�wheel�on�the�opposite�side.

When�assessing�damage,�an�initial�vehicleinspection:

• involves�identifying�all�visibledamage�and�looking�for�indicatorsof�additional�damage�that�is�notvisible.

• considers�the�collision�energytransfer�and�absorption.

• determines�if�there�is�inertialdamage�inside�the�passengercompartment.

• involves�identifying�pre-existingdamage.

The�damage�appraiser�has�this�vehicle�raised�on�a�liftto�inspect�the�underbody�for�damage.

The�complete�damage�inspection�mayrequire�raising�a�vehicle�for�better�accessto�the�underbody.�A�complete�damageinspection�may�include�checking�forvisual�damage�indicators�and�may�requiresome�disassembly�of�a�vehicle�to�helplocate�hidden�damage.

Before�the�vehicle�starts�the�repair�process�in�thisfacility,�it�is�disassembled�and�undamaged�parts�areproperly�stored.

Hidden�damage�can�be�found�by�doinga�partial�disassembly�as�part�of�the�repairblueprint.�Repair�blueprinting�is�theprocess�of:

• developing�a�complete�andaccurate�damage�report.

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• identifying�the�full�extent�ofdamage�before�repairs�are�startedon�a�vehicle.

• an�orderly�removal�of�parts(teardown),�at�least�enough�toaccess�and�identify�all�of�thedamage.

• determining�the�total�repaircost.�This�includes�identifyingall�parts�needed�down�to�theclips,�moldings,�and�one-time-usefasteners�to�ensure�all�the�parts�arein-house�before�work�is�begun.

• making�repair�or�replace�decisionsas�the�damage�is�revealed.

• taking�measurements.

The�red-colored�vehicle�on�the�upper�left�portionof�this�measurement�system�printout�shows�that�thevehicle�has�damage�to�its�structure.

Measurements�made�during�the�estimatingprocess:

• are�quick�checks�designed�todetermine�if�the�vehicle�structureor�suspension�parts�were�moved�ordamaged.

• may�be�made�using�an�electronicmeasuring�system�that�will�providea�printed�record�of�the�results.

Deployment�of�the�restraints�on�this�vehicle�mayrequire�additional�parts�to�be�replaced.�(left)�Thisairbag�parts�replacement�chart�is�located�in�the�P-pages�of�the�estimating�guide�from�the�estimatingsystem�being�used.�(right)

When�a�vehicle�has�deployed�airbags,replacement�and�inspection�items�needto�be�determined.�Airbag�replacementcharts�can�be�referenced�to�determine�therequirements�for�a�specific�vehicle.

Airbag�part�replacement�charts:

• list�mandatory�part�replacementrequirements�after�an�airbagdeployment.

• give�inspection�guidelines�forwhich�parts�must�be�inspectedafter�an�airbag�deployment.

• can�typically�be�found�inthe�vehicle�maker�serviceinformation,�estimating�guides,�orcomputerized�estimating�system

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Vehicle�service�information�is�being�accessed�on�thislaptop�computer.

The�vehicle�service�information�mayprovide�useful�information�for�damageappraisers�when�determining�therepairability�of�damaged�parts�on�avehicle.

The�I-CAR�website�provides�links�tovehicle�maker�service�informationwebsites.�An�additional�source�for�links�tovehicle�maker�websites�is�the�OEM�OneStop�TechInfo�web�page.

Service�information�may�provide�information�aboutparts�available�for�a�repair.

Service�information�may�include�detailedinformation�for:

• special�tools,�products,�andequipment�that�will�be�required�tocomplete�a�repair.

• specific�repair�procedures.�Thevehicle�service�information�mayprovide�specific�procedures�or�avariety�of�options�for�repairing�adamaged�part.�Replacement�partnumbers�may�also�be�included�inthe�repair�procedure.

• material�usage�charts.�Materialusage�charts�or�listings�may�specifythe�types�and�strengths�of�steelused�for�various�parts.�Materialusage�charts�may�include�therepairability�of�certain�parts.

• measurements,�such�as�underbody,underhood,�and�side�aperturedimensions.

I-CAR�provides�several�vehicle-specific�trainingcourses.

Additional�sources�of�information�canbe�found�on�the�I-CAR�websiteunder�theTechnical�Information�pull-down�menu.Choices�include:

• the�Advantage�Online.�Thissection�includes�archives�of�I-

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CAR�technical�articles�dating�backto�1989�up�to�the�most�recentAdvantage�Online�article.

• the�Top�Technical�Inquiries.�Thissection�provides�a�list�of�thetop�vehicle�technical�inquiriesreceived�at�the�I-CAR�Tech�Centre.

• the�Airbag�Parts�ReplacementCharts.�This�section�provides�a�listof�all�parts�that�must�be�inspectedand/or�replaced�following�anairbag�deployment�for�all�makesand�models�of�vehicles�datingback�to�1993.

• the�Partial�ReplacementRecommendations�matrix.�Thismatrix�may�be�referenced�todetermine�if�a�partial�replacementprocedure�exists�for�a�vehicle,which�could�save�time�andexpense�of�purchasing�andsearching�through�unnecessarysources.�Information�in�this�matrixis�specific�to�individual�vehiclemake,�model,�and�year.�Partialreplacement�refers�to�installing�aportion�of�a�part�at�factory�seamsor�at�a�sectioning�location.

• UPCR.�These�are�general�repairprocedures�for�all�parts�of�avehicle.

I-CAR�provides�several�vehicle-specifictraining�courses�that�provide�informationon�vehicle-maker�guidelines�and�vehicle-specific�repair�procedures.

The�Mitchell�Refinishing�Materials�Guide�can�bereferenced�when�determining�paint�and�materialscosts.

The�Mitchell�Refinishing�MaterialsGuide�is�one�source�for�informationregarding�paint�code�locations,�paint�codeexplanations,�and�paint�and�materialscosts.

Paint�makers,�such�as�PPG,�Spies-Hecker,�and�BASF,�provide�information�todetermine�the�correct�refinish�types�andmaterials.

Topics�discussed�in�this�moduleincluded:

• why�damage�reports�are�written.• when,�where,�and�by�whom

damage�reports�are�written.• processes�that�are�done�when

writing�a�damage�report.• information�sources�used�when

writing�a�damage�report.