Metal Body Repair PDF

SUBCOURSE
OD1653
EDITION
7
METAL BODY REPAIR
USARMYREPAIRSHOPTECHNICIAN
WARRANTOFFICERADVANCEDCOURSE
MOS/SKILLLEVEL:441A
METALBODYREPAIR
SUBCOURSENO.OD1653
USArmyCorrespondence
CourseProgram
7CreditHours
GENERAL
Thepurposeofthissubcourseistointroducevariousoperationsrequiredto
repair damaged vehicles and specifically describe the repair procedures
requiredforproperglass,radiator,andfueltankrepair.
Sevencredithoursareawardedforsuccessfulcompletionofthissubcourse
whichconsistsoftwolessonsdividedintotasksasfollows:
Lesson1:OPERATIONSREQUIREDTOREPAIRDAMAGEDVEHICLESANDCOMPONENTS
TASK1:Describetheoperationsrequiredtorepairdamagedvehiclesand
components.
Lesson2:OPERATIONSREQUIREDFORGLASS,RADIATOR,ANDFUELTANKREPAIR
TASK1:Describetheoperationsrequiredforproperglassrepair.
TASK2:Describetheoperationsrequiredforproperradiatorrepair.
TASK3:Describetheoperationsrequiredforproperfueltankrepair.
METAL BODY REPAIR - 0D1653

TABLEOFCONTENTS
Section
Page
TITLE.................................................................
TABLEOFCONTENTS.....................................................
ii
Lesson1:
OPERATIONSREQUIREDTOREPAIR
DAMAGEDVEHICLESANDCOMPONENTS.............................
Task1:Describetheoperationsrequired
torepairdamagedvehiclesandcomponents.........................
PracticalExercise1..............................................
48
AnswerstoPracticalExercise1...................................
50
Lesson2:
OPERATIONSREQUIREDFORGLASS,
RADIATOR,ANDFUELTANKREPAIR..............................
55
forproperglassrepair...........................................
55
forproperradiatorrepair........................................
67
forproperfueltankrepair.......................................
87
PracticalExercise2..............................................
96
AnswerstoPracticalExercise2...................................
99
REFERENCES............................................................
101
ii
METAL BODY REPAIR - OD1653
THISPAGEINTENTIONALLYLEFTBLANK
iii

STUDENTNOTES
iv
METAL BODY REPAIR - OD1653 - LESSON 1/TASK 1

LESSON1
OPERATIONSREQUIREDTOREPAIRDAMAGED
VEHICLESANDCOMPONENTS
TASK1. Describe the operations required to repair damaged vehicles and
components.
CONDITIONS
Within a selfstudy environment and given the subcourse text, without
assistance.
STANDARDS
Withinthreehours
REFERENCES
Nosupplementaryreferencesareneededforthistask.
1.
Introduction
In order to replace or repair damaged sections of an auto body, the

technician mustbeginwithathoroughunderstandingofhowthevehicleis
constructed. The major elements of auto body construction are therefore
discussedfirstinthislesson.Althoughtheconstructionoftheautobody
may seem complicated, with conscientious study and a sincere desire to
learn,themajorprinciplesmaybeacquiredquickly.
Without a clear understanding of the basics of vehicle construction and
assembly, itwould be very difficulttofollowcorrectrepairprocedures.
Work improperly done, because of a lack of knowledge about vehicle
construction, may result in unsafeconditionswhichendangerthelives of
driversandtheirpassengers.
Vehicle body construction is a broad topic and cannot be treated
exhaustivelyinthislesson. Themechanicwhoplanstodomajorcollision
repair

work should also study body constructiondiagramsinmanualspublished by
the leading auto manufacturers. Suchstudy,plusrepeatedexamination of
actual vehicles, is the best course to follow in gaining a thorough
familiaritywithvehicleconstructionprinciples.
Thesuccessfulautobodytechnicianlikestodomechanicalworkandhasthe
abilitytoplan,stepbystep,eachjobthroughcompletion.Seldomaretwo
jobs the same; so the technician should be creative in planning the work
procedure. Because the outer panels are shaped to relate to the total
design of the vehicle, the technician must also have an artistic
appreciationforthework.Prideinworkisveryimportantinafieldwhere
aslightimperfectioncanruinawholejob.
Typically,thetechnicianbeginsbyremovingtrimcomponents,bodyhardware,
andaccessoriesinordertogainaccesstothedamagedmetalbyaprocess
calledbumping,usingdollyblocksandspecialhammers. Ifdamageismore
extreme, hydraulicjackingequipmentmaybeusedtoalignadamagedarea.
Tinynicksanddentsareusuallyremovedwithspecialpicktools.
Eachdamagedvehiclepresentsaspecialrepairproblembecauseofthemany
kinds of damage which may occur. The technician seldom works at one
particularjobforanygreatlengthoftime. Heorsheisexpectedtobe
skillfulinmanywidelydifferentareasofwork,andtohavetheabilityto
seetheentirejobthroughtocompletion. Inordertobesuccessful,the
technicianshouldhaveagoodunderstandingofvehicleconstruction,seeing
howandwhythepartsfittogethertoformthetotalvehiclebody.Pridein
workmanship is very important. Failure to do quality work at any point
duringtherepairmaycausegreatproblemslateron.
2.
BodyandFrameConstruction
a.
BodyConstruction.
(1) Bodies. Passenger cars and truck bodies differ a great deal in
constructionbecauseofthedifferentpurposesforwhichtheyareintended.
However, eachhasaninnerandouterconstruction. Outerconstructionis
consideredthatportionofa

panelorpanelswhichisvisiblefromtheoutsideofthevehicle.Included
in theinnerconstructionareallbraces,brackets,panels,etc.thatare
used to strengthen the vehicle body. A general assumption is that inner
constructioncannotbeseenfromtheoutsideofthevehicle.
(2) BodyConstruction.Themainbodycomponentsareshowninfigure1.
Cowl or dash panel assemblies for the front end of the body are usually
formedbyassemblingseveralsmallerpanels.Thesearethecowlupperpanel
andthecowlsidepanelsthatarejoinedbyweldsintoonesolidunit.The
cowlextendsupwardaroundtheentirewindshieldopeningwiththeupperedge
of the cowl panel forming the front edge of the roof panel. Windshield
pillars are part of the cowl panel. They are the narrow sloping
constructions at either side of the windshield opening. The cowl is
sometimes referred to as the fire wall. The instrument panel is usually
consideredpartofthecowlpanel.
FIGURE1.MAJORSEDANBODYCOMPONENTS.

(3) Roof Panel Assembly. The roof panel is one of the largest body
panels,butitisalsooneofthesimplestinconstruction. Usually,the
roof is a onepiece steel construction. Some Army combattype wheeled
vehicleshaveacanvastop.
(4) FloorPanAssembly. Thefloorpaniscomposedofseveralsmaller
panelsthatareweldedtogetherorsecuredtooneanotherbyboltstoform
one single unit, as shown in figure 2. Most floor pans are irregularly
shaped. They are indented or formed into bends to give strength to the
entirefloorstructure.
FIGURE2.FLOORPANASSEMBLY
(5) RearQuarterPanel. Therearquarterpanelisanintegralpartof

thefender. Therearquarterpanelhasbothinnerandouterconstruction.
The outer construction or outer panel is smooth, except for the breaks
caused by the design of the vehicle. The inner construction of a rear
quarter panel is made up of many strong reinforcement brackets welded or
boltedtogethertoformasingleunit.
(6) Doors. Doors are composed of two main panels: outer and inner.
Bothpanelsarenormally

of all steel construction. Doors derive most of their strength from the
innerpanel.Theinnerpanelactsasaframeforthedoor.Itismadewith
offsets and holes for the attachment of inner door hardware. The outer
panel flangesovertheinnerpaneledgestoformasingleunit. It also
provides an opening through which the outside handle protrudes. In some
instances,aseparateopeningisprovidedforthelock.
(7) DeckLid. Thedecklidisanotherdoorthatallowsaccesstothe
luggagecompartment.Itconsistsofanouterandinnerpanel.Thesepanels
arespotweldedtogetheralongtheirflangededgestoformasingleunit.
b.
FrameConstruction.
(1) An understanding of the construction of the frame is extremely

important,sinceitisthefoundationonwhichthevehicleisbuilt.Frames
of all types to fit all conditions are described and illustrated in this
section. Framescanbeconstructedfromchannelstock,Ibeam,angle,T
stock,Zstock,tubing,flatplates,oracombinationofanytwoormoreof
thesestocks. Framesareusuallywiderattherearthanthefront. This
permitsashorterturningradiusbyallowingmoreroomforthefrontwheels.
It also allows more space for supported load carrying at the rear. The
heaviest cross member is usually mounted under the front portion of the
engine.
FIGURE3.PASSENGERCARFRAME.

(2) Atypicalpassengercarframeisshowninfigure3(ontheprevious
page). ThisframehasanXmemberinthecenter. Forthisreason,itis
referred to as an Xtype frame. Youcanalsoseefromthisillustration
what is meantbytheterm "drop"usedinconnectionwiththeframe. The
mainpartorcenteroftheframeisdroppeddownbetweenthefrontandrear
wheels.Repairstoausedbodyandframearebasicallythesameasrepairs
toseparatebodyandframetypevehicles.
(3) Metal repair procedures and straightening and squaring operations
all apply, including the use of the hydraulic jack or other equipment.
Avoidconcentratingstressesinonespotbytheuseofblocksorplatesof
woodormetalinordertodistributetheforce.Avoiduseofflamewelding
inrepair,ifpossible,anddonotapplyexcessiveheattothemainframe
members, as annealing and loss of strength may result. Most collision
damagemayberepairedbytheuseofjacksandbumpingblocksorironsto
reshape the damaged panels back to their original form. Usually, it is
uneconomical to repair a body which has sustained damage to the main
structuralmemberssevereenoughtocollapsetheboxsectionmembers.
(4) Surfacestobeweldedmustbefreeofdirttopreventcontamination
oftheweld.Useawirebrushorgrindingwheeltoremoverust,paint,and
undercoating. Allrepairweldingwillbedonebytheelectricarcprocess
if possible. It is suggested that a lowhydrogen electrode, 3/32 inch
diameter,beused.
(5) Dependinguponindividualconditions,spotweldsmayberepairedby
drillingoutandplug,puddle,skipweld,continuousweld,oranarcbeador
filletmaybelaidalongthepanelatthatpoint.
(6) If 1/4 inch crown dimensions are exceeded, crossmembers must be
straightened. Removal of the engine is necessary. Straightening can be
accomplished with the use of Cclamps, hydraulic body jacks, and
attachments.Heatshouldnotbeappliedtoaidthestraighteningprocess.
(7) Withtheexceptionoflightvehicles,commercialvehicleframesare
usually built flat. Light commercial vehicles are usually built on
passenger carframes,oronaslightlystrongeradaptationofapassenger
carframe.Largetruckand

busframesaremadeflatwithoutanydrop,sinceaflatfloorforthecargo
orpassengercarryingspaceishighlydesirable.Alowcenterofgravityis
not as important a consideration for commercial vehicles as it is with
passengercars.
(8) Separatepartsofautomobileandtruckframesarerivetedtogether.
Rivets areusedbecauseoftheirstructuralstrengthandtheirabilityto
givewiththeroadcondition.Beforeattemptingtorepairanyframe,itis
importanttomakeaninspectiontodeterminewhat,ifany,damageorframe
misalignment exists. Frame members often lose part of their original
strength during the straightening process as a result of heating or
excessiveworkingtobringthepartsbackintoalignment. Itispossible
thatsomeframeshaveinherentweaknesses. Truckoperationsmayresultin
shockloadswhichthemanufacturerhasnotanticipated.
FIGURE4.FRAME(CARGO,SHOPVAN,TANKER).

(9) In these cases, the frame will have to be reinforced. For
additional information on repair of frames, consult TB 9230024740.
Figure4(onthepreviouspage)showsamilitarytruckchassiswhichisa
standardframeforthecargobody,shopvanbody,tanker,repairvanbodyof
the21/2ton,6x6truck.
3.
MetalBodyTrimandHardware
a. General.Inthevehiclebody,windowopeningsareunsightlywhenviewed
from the inside. They must havedecorativetrimtogivethemafinished
appearance. In the vehicle body, finishing touches which are put on the
outside as well as the inside are called either trim or hardware. On
sedans,inadditiontoprovidingeyeappeal,sometrimisfunctionalaswell
as decorative and contributes to the comfort and convenience of the
passengers.
b. Trim. Moldings,floormats,armrests,headlinings,doortrimpads,and
weatherstrippingareknownastrim.
c. Hardware. Door handles, window regulator handles, locks and window
regulators, latches, hinges, seats, and seat adjustments are known as
hardware.
d. Grilles.Grillesaresometimesreferredtoastrim.Thiswouldmakeit
the largest single unit of trim. Grilles are usually made from several
piecesofsteelwhicharefastenedtogetherbynutsandboltsorbywelding.
In some cases, grilles are made from cast aluminum, white metal alloy,
stainlesssteel,andsteelstampings. Oncombattypevehicles,thegrille
isreferredtoasabrushguard. Thisgrille(3/4tonandover)ismade
from lowcarbon steel stock and welded in place to form one single unit.
The1/4tonvehiclegrilleisaonepiecesteelstampingboltedinplace.
Grillesareusuallyfastenedinplacebyboltswhichattachittothefront
fenders. Brackets and supports are also provided which anchor it to the
frame.Grillesarealsofabricatedfromfiberglassandlaminatedmaterial.
e.
Moldings.
(1) Passenger car moldings are used freely both inside and out.
Moldingsdifferintypeandstyle

dependingontheiruse.Moldingsaresecuredinplacebyretainers,screws,
and special clips, except that moldings used around windshields and rear
windowsareheldinplaceentirelybyscrews.
(2) Combattype vehicle windows have very little, if any, outside
moldings. Attractive appearance is not the main desire of a combattype
vehicle.Camouflageisoftennecessaryduringcombatandifthevehicleis
cluttered up with moldings shining in sunlight, troop positions could be
revealed.
(3) Generally,theweatherstrip,whichsecuresthewindshieldglassto
thevehicle,ischanneledtoreceivetheoutsiderevealmolding(thechrome
strip on the outside of the vehicle around the windshield glass). The
revealmoldingisheldinplacebyitsownspringbackafteritisinserted
intotheweatherstrip.
(4) Theinsidegarnishmolding,whichfitsontheinsideofthevehicle
aroundthewindshieldglassandotherwindowopenings,isfastenedinplace
withsheetmetalscrews.Anotherarrangementofwindshieldinstallationis
showninfigure5.
(5) Windshieldsoncombattypevehiclesarenormallyheldtogetherbya
metalframeandsheetmetalandmachinescrewsandareattachedtothebody
byhingesandbrackets.
FIGURE5.CROSSSECTIONOfWINDSHIELD
WEATHERSTRIPPINGANDMOLDING.

(6) Moldingsusedaroundtherearwindowsareusuallyinstalledinthe
samemannerasthewindshields.
(7) Beforemoldingscanberemoved,itisnecessarytobreaktheseal
betweentheweatherstripandthebody.Thiscanbedoneeasilybyinserting
athinknifebladebetweentheweatherstripandthebody,thenrunningit
alongthelengthofthemolding.
(8) Combattypevehiclesdonotuseagarnishmolding.Thedoorusually
isofaonepiececonstruction.Thedoorglasshasasheetmetalframethat
goesaroundit.Theentireunitissecuredtothelowerglasschannelwith
machinescrews.
f.
Handles.
(1) Onsomemakesofsedans,thelockonthefrontdoorisconstructed
integrallywiththedoorhandlepushbutton. Onothermakes,thelocking
mechanismisseparatefromthehandle.Aseparateopeninginthedoorpanel
isprovidedforthelocktobeinstalled.
(2) Outsidedoorhandlesextendthroughtheouterpanelintotheinner
panelwherethelinkageisconnectedtooperatethelatchmechanism. Door
handlesarefastenedinplacebymeansofamachinescrewthroughtheinner
panel.Combattypevehicle'soutsidedoorhandlesarefastenedinplaceby
twoscrewswhicharescrewedintotheoutsidedoorpanel.
(3) Inside door handles are held in place by a pushfit pin that is
concealed under the escutcheon when it is in place. An internal spring
allowstheescutcheontobedepressedforaccesstothisretainingpin.
(4) Anothertypeofdoorhandlewhichisusedonsomevehicleshasan
integral handle and escutcheon held in place by a spring retainer or
horseshoeclip.
(5) Itisnecessarytouseaspecialpairofthinnosepliers,oraflat
tool made for this type of retaining pin, to remove the pin before the
handlecanberemoved.
10

g.
DoorTrimPads.
(1) Sedandoortrimpadsareusedtoconcealthelowerportionsofthe
insidepanelofdoors.Thepadsareusuallyprefabricatedandassembledto
the door as one unit. They are held in place by sheet metal screws and
varioustypesofspringclips.
(2) Combattypevehicledoorsaremadeinonepiece. Theonlyopening
in the door (loading hole) is covered by a piece of sheet metal and is
securedinplacebysheetmetalscrews.
4.
MetalBodyTools
a.
Hammers.
(1) Dinginghammer(A) (figure6). Itisageneralpurposehammerfor

use on anybodypanel. Ithasa13/8inchsquarefaceand19/16inch
round face, and is made from dropforgedalloysteelwhichhasbeen beat
treated.
FIGURE6.TYPESOFBODYANDFENDERHAMMERS.
11

(2) PickHammer(B)(figure6onthepreviouspage).Thepaintedshank
ofthishammerisusedtoraisesmall,lowspotswhencrossfiling.Ithasa
19/16inchroundfaceandacurvedshanktaperingtoapoint.Thebullet
type pick hammer (not shown) is designed for use on all industrial metal
finishingandgeneraldingingwork.
(3) TaperShankHammer(C). Designedforthelatestmetalbodiesand
fenders, it is used for reshaping all beads, moldings, headlamp insets,
reveals,andlouvers.Ithasawidechiselfaceforrapidpicksurfacingin
largeareas.
(4) RoughingHammer(D).Itscurvedshankreachesplacesnotaccessible
tohammersofordinarydesign,anditsroundfaceisidealforworkingan
extraheavygagemetal.
(5) Wooden Mallet (E). It is for use in connection with hotmetal
shrinking,andfordingingsoftmetalsuchasaluminum,copper,andbrass.
Itwillnotchipunderordinaryusage.
(6) OffsetCrossPeenHammer(F).Itsoffsetsquarefaceaffordsample
clearance without danger of striking adjoining panels. Its high crown
crosspeenisdesignedfordeepandnarrowpanelsandreturncontours.The
highcrownmayalsobeusedinconjunctionwiththeshrinkingdollytocold
shrinkpanelsorsinkwelds.
b.
Dollys.
(1) HeelDolly(A)(figure7Aonthefollowingpage).Itisshapedlike
theheelofashoe,roundfaceononesideandflatontheother.Itmaybe
usedasageneralpurposedolly.
(2) HighCrown(GeneralPurpose)Dolly(B).Itisprecisiongroundfor
highcrowncontoursandisusedingeneralbodyrepairwork. Thistoolis
madefromdropforgedalloysteel.
(3) LowCrownDolly(C).Itisusedonalllowcrownpanels.Thehooks
onthedollyareusedonfenderbeads,dripmoldings,andsharp,concaved
moldings.
(4) Shrinking Dolly (D). Itisaspeciallydesignedcombinationhigh
andlowcrowndolly.Ithasninedistinctcontourcombinationsforhotand
12

FIGURE7A.DOLLYS.
coldshrinking.Ithaswideandnarrowtrenchinggroovesforsinkingwelds.
(5) HeavyDutyRoughingDolly(E)(figure7A).Ithasaconvenientgrip
andgreaterheighttofurnishextrabackingforheavydutyhammering. It
maybeusedinplaceofaroughinghammerforroughingoutsmalldents.The
lipattheendofitsfaceisusefulforreshapingturnedunderflanges.
c. DripMoldingPliers(figure7B).Theiraccuratelyformedworkingfaces
permit extremely rapid roughing out for finishing with a suitable spoon.
Madefromdropforgedsteel,theyareindispensableforpullingoutcrushed
dripmoldings.
FIGURE7B.DRIPMOLDINGPLIERS.
13

d. BodySpoons.Bodyspoonsaregenerallyusedfordrivinghighspotsback
to their normal position withoutdisturbingthesurroundingsurface. The
workingsurfaceofeachspoonisdesignedforaspecificpurpose.Themore
commonvarietiesofspoonsarethefollowing:
(1) CowlBracket(A) (figure8). Designedespeciallytohookoverthe
fenderbrackets,itisusedtoworkovercowlstrainersandcowlbrackets
fromposttodashandeitherhighorlowcrownsurfaces.Itmaybeusedas
adolly,sothewheelcanbekeptonwhenreachingadent.
FIGURE8.TYPESOFBODYANDFENDERSPOONS.
(2) DoubleEndandLowerBeckQuarterPanelSpoon(B). Itisusedfor

removing dents on quarter panels around rear pillars, behind inner
construction,andbehindbackpanelstrainers.Itmaybeusedforremoving
dentsfrombehindsills.
14

(3) SurfacingSpoon(C)(figure8onthepreviouspage).Itisusedfor
spring hammering operations witheitherthemalletorbumpinghammer, and
surface finishing. It is usefulonallfenderrepairsandonhigh crown
areas.
(4) DoubleEndHeavyDutyDrivingSpoon(D).Thisisageneralpurpose
utilityspoonwithawidevarietyofuses.Itisusedtosetinsideseams
offrontfenders,bumpingtoprailpanels,headlamphousings,hoodlouvers,
and straightening and finishing drip molding and back panels. It may be
usedforgeneralbeasingwork,lightinghingepins,raisinglowspots,and
forworkaroundtheventilatorinthecowlassembly.
(5) Caulking Iron (E). A caulking iron is sometimes called a fender
beading tool. It is a specially designed double end, heavy duty beading
toolusedforstraighteningallreversebeadonfenderswithnowire,and
turnedunderflangededges.Itmaybeusedonreturnflangesorhoods,and
foraligninginnerconstructiononbodypanels. Itshammerpadsprovidea
baseforhammeringoperations.
(6) DoubleEndDoorandSidePanelSpoon(F).Itsprecisiongroundface
sakes it usefulasadolly blockindirecthammering. Itisdesigned to
reach the hardtoget places behind inner construction on doors and cowl
panels.
(7) SpecialDoorandSidePanelSpoons(G).Theunusuallengthofthis
spoon, together with its shape, enables the workman to reach far behind
constructionandremovebumpsfromdoorsandtrunklidswithoutcuttingout
theinnerconstruction.
e.
FileBolderandBlade.
(1) AdjustableFileBolder. Thistoolquicklyadjustsfromanextreme

concavetoanextremeconvexprofile. Ithasmaximumutilityforfilinga
wide variety of contours: round oval corners, upper and lower bracket
panels,cowls,hoods,andtoprailpanels. Itisusedforflatwork,high
andlowcrowns,andonsweepsurfaces.
(2) VixenFileBlade. Thisbladeisdetachablefromtheholderandis
different fromanyothertypefile. Thesebladesareaccuratelymachined
withunbrokencuttingedgesabout1/8ofaninch
15

apart. Each cutting edge is curved with the cutting edge on the convex
side.Thisbladehasthecuttingedgesoneachside,andtheteethrunin
oppositedirectionsofeachothertoallowthebladetobeturnedoverwhen
onesidebecomesdullandunusable.
(3) MapleSolderPaddle.Thispaddleismadefrommaplewoodbecauseit
doesnotsplitaseasilyasotherwoods.Itisusedtoshapehotsolderto
thedesiredshape.Itisusedwithmotoroil,beeswax,ortallowtoprevent
thehotsolderfromstickingtothefaceofthepaddle.
5.
MetalBodyEquipment
a.
HydraulicBodyJack(figure9onthefollowingpage).
(1) Types.
(a) Direct Acting Jack. This type jack has the power unit or
hydraulicpumpintegralwiththeram.Theactionmaybeonlyonedirection,
oritmayworkineitherdirection,pushpull.
(b) RemoteControlledJack. Inthistypejack,thehydraulicpower
supply is separated from the ram unit of the jack. The two units are
connectedbyareinforcedrubberhose.
(2) RemoteControlledJackComponents.
(a) Pump(B) (figure9). Itishandoperated,withallcontrolson
theunit.Thepumpalsoservesasthereservoirforhydraulicoil.Theoil
levelshouldbeperiodicallychecked.
(b) Ram (V). Threads on the ram are for attaching other jack
attachments. Ifthejackisusedwithoutattachments,athreadprotector
mustbeusedonthetopoftherambody.
(c) FlexibleRubberHeads(K). Twosizesofrubberheadssuitmost
bodyneeds.Rubberheadsaregenerallyusedondrypaintedsurfacesbecause
theywillnotslipormarthesurface.Theseheadsshouldnotbeusedinor
near oiled surfaces as they can slip and cause further damage. Internal
threadsareprovidedforotherjackattachments.
16

FIGURE9.HYDRAULICBODYJACKANDATTACHMENTS.
(d) ChainPullPlate(E)(figure9).Thisplateisusedinmostpulling
operations. The plate has internal threads with slots on both sides for
securingchains.Itattachestotherambody.
17

(e) SlipLockExtension(F)(figure9onthepreviouspage).Thistool
givessixinchesofpromptadjustmentinpushingoutlargeareas.Adouble
friction lock holds securely at desired lengths, and is adjusted by a
convenientdoubletriggerrelease.
(f) RockerSpoon(G) (figure9). Speciallydesignedforbodywork,it
is held and locked in place by a hexagon pin. It may be set in many
differentpositions.Theselectionofthespoonpositionisgovernedbythe
curvatureofthebody,thebodybendordent,andamountofworkingspace.
(g) Spreading Wedge (H). This tool is used for forcing out large or
small concave areas and can be closed to one inch and opened to three
inches.
b. Electric Disk Sander. The disk sander may be used to remove paint,
reveal low spots, shape the contours of areas built up with solder, sand
downwelds,removeexcesssolder,removerust,andremovedeepscratchesby
using a fine abrasive sanding disk. It may be equipped with a flexible
grindingwheeltoserveasagrinderonthicksectionsofmetal.
(1) BackingPlate.Inmostgrinding,thediskisplaceddirectlyonthe
slightly flexible backing plate. Hard rubber and plastic can be used as
backingplates.Ifa9inchsandingdiskisused,itshouldhavea7inch
backingplate.The7inchbackingplatewillallowthe9inchsandingdisk
outeredgetobecutdownwhenithasbecomeworn,increasingthedisklife.
Sandingdisksaresecuredinplacebyaflatplatenutthatisscrewedonto
themotordriveshaftandpermitseasyinstallationandremovaloftheplate
nutwhenchangingtornorwornoutdisks.
(2) SandingDisks.
(a) The coating abrasive disk does the cutting. Selection of the
rightgritandcoatingforeachjobisimportant.
1 Five different minerals are commonly used for manufacturing
abrasives. Threeofthese,garnet,flint,andemery,arenaturalmineral
abrasives.Theothertwoarealuminumoxideandsiliconcarbide.
18
METAL BODY REPAIR - OD1653 - LESSON l/TASK 1

2 Garnet, a semiprecious jewel, is the most important of the
naturalminerals.
3 Emery and flint break down easily and are better suited for
householdusethanforindustry.
4 Fordrysanding,highqualityhidegluesareusedforanchoring
abrasivegrainstothediskbacking. Forwetsanding,resinsareusedas
thebondingagent.
(b) Coatedabrasivesfallintotwoadditionalclassifications,basedon
howwidelythemineralsarespaced.Ifthemineralsareclosetogether,it
is referred to as close coat. If the minerals are widely spaced, it is
referredtoasanopencoat.
(c) Closecoatabrasivesareappliedinsuchquantityastocompletely
coverthebacking.
(d) Opencoatabrasivesareappliedsoastocoverfrom50to75percent
ofthebacking.
(e) The open coating provides increased pliability and good cutting
speed under light pressures. Open coated abrasives are used where the
surfacebeinggroundisofsuchnaturethatcloselyspacedabrasiveminerals
would rapidly fill up, such as sanding paint or wood. Following is a
suggesteduseofthreeofthemostcommondisks.
1 TheNo.24diskiscoatedwithacoarseopencoatabrasive. It
mustbeusedwithreasonablecautiontopreventmakingdeepscratchesinthe
surface. Thisdiskismostgenerallyusedinroughsandingsurfacesthat
havebeenpainted. Sanduntilasmallvolumeofsparksisnoticedcoming
frombeneaththedisk;whentheseappear,stopsanding.
2 ClosecoatNo.36diskisusedforseveralpurposesinthebody
shop.Itismostgenerallyusedforremovingweldsandinplaceofthebody
fileinrevealinghighandlowspotsinthebumpingoperations.
3 Close coat No. 50 disk has only one function: performing
finishing operations on metal surfacessuchassteelandsolderedpanels.
ThisdiskwillremovescratchesleftbyNo.24andNo.36sandingdisks.
19
METAL BODY REPAIR - ODl653 - LESSON 1/TASK 1

(f) When operating the sanding machine, hold it as flat as possible
without allowing the drive shaft nut to come in contact with the surface
being ground (figure 10). Hold the sander so that only 1 1/2 to 2 1/2
inchesoftheouteredgeofthediskisincontactwiththesurfacebeing
ground.Thesandermustneverbetiltedsothatonlytheedgeofthedisk
contacts the surface. Failure to observe this will cause gouges or deep
scratchesinthemetalthatwillbehardtoremove. Movethesanderfrom
lefttoright,overlappingthepreviousstrokewitheachnewstroke. Make
thecuttinglinesascleanandstraightaspossible.Movethesanderinthe
same manner whether you are removing paint, roughgrinding, or finish
sanding.
FIGURE10.
6.
CORRECTANDINCORRECTMETHODSOF
USINGTHEELECTRICSANDER.
MeasurementPrinciples
a. Damagetothebody'sinnerconstructionortotheframeofavehiclecan
beseverebutnotbeapparent.Failuretocheckforandcorrectsuchdamage
can result in poor fitting doors, hoods, or fenders; faulty steering
control;andmanyotherproblems.Thepossibilityofthesefaultsmakesa
20

number of measurements necessary throughout the correction of collision
damage.Themeasurementstakengenerallyarenotnecessarilymadeininches
orfeet,butratherarecomparativemeasurementsinwhichonemeasurementis
compared,bymeansofabodytram,toanotherthatshouldbeequal(figure
11).
FIGURE11.COMPARATIVEMEASUREMENTS.
Vehiclebodiesareregardedashavingtwosideswhichareexactlythesame.
Therefore,ifonlyonesideisdamaged,itcanbecomparedwithmeasurements
takenontheundamagedside.Thereismoretocomparativemeasurementthan
comparing a damaged panel with a similar but undamaged panel. Occasions
will arise when both sides of a vehicle are damaged, and it will be
impossibletocompareonesidewiththeother.
b.
ComparativeMeasurement.
(1) A metal picture frame is represented by (A) (figure 11) with

oppositesidesofequallength.Therefore,thediagonalsXandYareequal.
21
METAL BODY REPAIR - OD1653 - LESSON l/TASK 1

(2) If the square is distorted, as shown in (B) (figure 11 on the
previouspage),thediagonalsarenolongerthesamelength;Yisnolonger
thanX.
(3) Ifthisfigureframe(B)isvisualizedwithmovablecorners,itcan
beseenwherepressuremustbeappliedtomakeitsquare;atthecornersof
theYdiagonal.
(4) The original length of either the sides or diagonals need not be
known. By making comparative measurements of the diagonals, it will be
shownthatwhentheyareagainequal,theframeisagainperfectasitwas
in(A).
(5) In (C), it is possible for the diagonals to be the same if the
distortion is exactly at the mid point of side (A). Therefore, by a
comparisonofsides,(A)canbestraighteneduntilbothside(C)andside
(A) are thesame length. Theseillustrationsshowhowitispossible to
alignabodyorframebymeasuringthebodyorframealone.
FIGURE12.DIAGONALSOFCUBESARE
ALWAYSOFEQUALLENGTH.
22

(6) When an entire section of a vehicle is knocked out of alignment,
another aspect of Xchecking measurement must be considered. The body
proper can be considered as a cube. It is a simple matter to determine
whether or not a cube is square by checking the diagonals from opposite
cornersasshowninfigure12onthepreviouspage.
(7) The diagonals checked should be from one corner of the box to
anothersothattheycrossintheexactcenterofthecube.
(8) This same principle can be applied to measuring the cubelike
sectionsofanautomobilebody.
(9) Thismethodofcheckingcanalsobeappliedtocheckingonesection
withanothersection.
7.
BodyandFenderRepairTechniques
a. General. Restoringvehiclebodypanelsofsheetmetaltotheirnormal
contour after they have been damaged is referred to as metal bumping or
dinging. Everyjobinvolvedinmetalbumping,requiresfinehandwork. To
become a good metal body repairman, mastery of each phase of work is
required.Incollisionwork,useofthehammerisoneofthemostimportant
functions.
b.
AnalyzingDamage.
(1) The ultimate success of any collision repair job depends on the
accuracyoftheanalysisofwhatisdamagedandhowitoccurred.Collision
workmustbeapproachedonthisbasis,butgoesastepfurther. Notonly
mustyoufirstdeterminewhatiswrong,butyoumustestablishhowitgot
thatwayandtheorderinwhichithappened.
(2) Althoughthestraighteningofbodypanelsandfenderscomprisesthe
greatest volume of collision work, collision damage also occurs to the
mechanical parts of the vehicle. The repair of mechanical parts is an
important part of the total repair of collision damage. When you are
finished repairing a vehicle damaged in collision or one that has turned
over, it must run well, it must steer well, the brakes must operate
properly, andalloftheelectricalunitsmustbeinoperatingcondition.
Althoughthecorrectionofmechanical
23

difficulties caused by the collision involves other skills and techniques
thanarepracticedbythecollisionexpert,hecannotignorethemandmust
providefortheircorrection.
(3) Each part of the damage occurred in a certain order. It is
necessary to correct it in the reverse order of the way in which it
occurred. Studyingthedamagepermitsyoutoreconstructthesequenceof
eventswhichcausedthedamage,therebyprovidingtheproperorderinwhich
thedamageshouldbecorrected.
c.
RoughingandAligning.
(1) Afteranalyzingthedamage,thenextstepinbodyandfenderrepair
ismetalbumping(roughing)whichistheimportantunlockingandunrolling
operation. If this is done carelessly or hurriedly, new lines of strain
will probably be set up, stretching and bending the metal at such sharp
angles that a further rearrangement of the displaced fibers will be
impossible.
(2) Beforerepairingfenders,scrapeoffanytar,gravel,orroaddirt
underneaththedamagedpart. Anydirtleftontheundersidewillcakeon
thedollyblock,sothathammeringsmoothwillbeimpossible.
(3) The outside surface of the damaged fender or panel is then wiped
witharagwhichhasasmallamountofthinmotoroilsoakedintoit.This
removes dust and grit which would otherwise stick to the hammer face and
hindertheworkerfromsecuringasmoothsurface.Thelightreflectedfrom
theoiledsurfaceshowstheextentanddepthofthevariousbumps.
(4) Sincemetalbumpingandfinishingaresimplyamatterofhammering,
itshouldbelearnedattheoutsethowtousethehammeranddolly. The
simplesecretistomakeeveryblowofthehammerstrikethemetaldirectly
abovethedollyorspoon.
(5) Asimpleapplicationoftheuseofahammeranddollyblockisshown
infigure13(onthefollowingpage). Thedownstrokeofthehammerdrives
thehighspotdownontothefaceofthedollyblock,smoothingthemetal.
The dolly block absorbs the shock of the hammer blow and prevents the
damagedmetalfrombeingdrivendowntoofar.
24

Atthesamemoment,thedollyblockbouncesawayfromtheundersurfaceof
thedamagedmetalandquicklyreboundsagainstthelowspots,raisingthem
before the next stroke of the hammer. With free whipping blows of the
hammerontheoutsidesurfaceofthemetal,thetwohandtoolsrapidlysmooth
theroughspot.
FIGURE13.USINGHAMMERANDDOLLY.
(6) Nevergripthedollytightlyorapplyanygreatamountofpressure
onit,becausetheimportantautomaticbounceandreboundofthedollywill
belost.Mostrepairmennaturallydeveloparhythmof60to150successive
hammerblowsperminuteastheybecomeskillful. Bumpingisonlyamatter
of hammering the high spots downandbringingthelowspotsupuntil the
damagedmetalisagainevenincontour. Puttingthehighmetaldownfirst
isveryimportant.
(7) Figure14(onthefollowingpage)illustratesasimpledamagewhich
mayoccurtoanouterdoorpanel.Thearrowindicatesthedirectionofthe
damagingforce.Xmarkstheouterrimofthedamagedarea,andYmarksthe
pointofimpactofthehub.ThelineXYrepresentsacutatthebottomof
oneoftheVchannels.Zmarkstheflangededgeofthepanelwhichhasbeen
bentsharplybythepanel'scollapse.Itisalsolocked.
25

FIGURE14.SIMPLEDAMAGE.
(8) SinceridgeXisclearlythelastcreatedinthedamage,itisthe
first strain to be unlocked. Place a lowcrown dinging spoon on it (1)
(figure 15onthefollowingpage)andhammerthespoonsharply,directing
theblowsstraightattheridge.Thisunlocksthehighmetalandmovesit
backtowarditsoriginalposition.
Next,dingtheflangecornerZ,unlockingit.Theareasofmetalbetween0
andYandbetweenYandZarenowlyingunlocked,readytospringbackto
normal shape with very little help. Give this help with a mediumcrown
dollyblock(2)(figure15),unrollingthewavewithtwoorthreeblowson
the under side from 0 through Y. This unlocks the kinked metal at the
bottomoftheVchannelOY. RepeatingthisprocedurefromZtoYrestores
themetaltothepositionshownin(3)(figure15).
(9) Figure 16 (on page 28) illustrates the error of roughing out the
samedamagewithoutfirstreleasingthelockedridges.In(1)(figure16),
thecavedinmetalisbeingroughedoutbystrikingtheundersideatYwith
a dolly. This forces up a large area of the dent to nearly its normal
shape.Note,however,thatthestrainintheridgeXhasnotbeenunlocked;
the ridge does not come down to its normal place, but instead pulls the
panel down abnormally at H. This happens because the locked ridge X
reinforcedandstrengthenedthemetaloneithersideofit.Therefore,when
forceisappliedupwardatY,theridgeactsasafulcrum,pullingthemetal
downatHasitisforcedupatY.
26

FIGURE15.REMOVINGSIMPLEDAMAGECORRECTLY.
(10) Nowthatroughingouthasbeenstartedwithoutreleasingthelocked
ridge, the metal must be stretched to raise it to its original level as
indicatedbythedottedline.Somuchforceisnowrequiredtobringitup
toplacethatitbumpsandknotswhereveritisstruckbythedollyblock,
as shown in(2) (figure 16 on thefollowingpage). Equalizingall these
bumpsandknotsmeansalotofwork.In(3)(figure16),thedenthasbeen
roughedoutandthehammeranddollyareinplacetostartsmoothing.
(11) In(4)(figure16onthefollowingpage),thedentisrestoredtoa
normalshape. Note,however,thatitisanewshape. Notonlyhastime
beenwastedinunplannedbumping,butthemetalhasbeenstretched,asshown
bythedottedlines,so
27

FIGURE16.REMOVINGSIMPLEDAMAGEINCORRECTLY.
that the entire width of the panel, instead of only the damaged area,
requiresmetalfinishing.
(12) Alignment is squaring the damaged body of a motor vehicle by
restoringitscorrectshapeanddimensions.Misalignmentmaybecheckedby
observation,butmeasurementsaremoreaccurate.
(13) The best measuring method of checking, known as Xchecking, is
simply an application of the principle that the diagonals of a true
rectangle areequal in length. Someareasthatmustbechecked,such as
dooropenings,thefrontsection(areabetweenthecowlhingepillars),and
thecentersection(areabetweenthecentralpillars),arenotinthemselves
square,but
28
METAL BODY REPAIR - OD1653 - LESSON 1/TASK I

rectanglesmaybelaidwithinthemwhichprovidegooddiagonaltests.
(14) The measuring device, calledatram(figure17),isatelescoping
tubeequippedwithanextensionclampwhichfixesitasthemeasurementof
onediagonalforcomparisonwithanother.
FIGURE17.TRAM.
(15) Sincemostseverecollisionsdistorttheframeaswellasthebody
of the motor vehicle, the frame must be checked and straightened first.
Divideitintothreerectangles,usingascornersthefrontandrearspring
shacklesasinfigure18(onthefollowingpage).
ThenlaythetramatdiagonalAB';clampingitattheexactlengthofthe
diagonal. RemovethetramandcheckA'Btoseewhetherthislengthisthe
same.InthesamewaycheckBC'againstB'CandCD'againstC'D.Ifthere
is any deviation of measurements, do not check body alignment until
correctiveforceshavebeenappliedtobringtheframeintoline.
29

FIGURE18.XCHECKINGFRAMEALIGNMENTWITHTRAM.
(16) Misalignmentofadooropeninginabodyisgenerallycheckedbythe
fitofthedoor. However,itmayalsobecheckedbythetramasshownin
figure19(onthefollowingpage).Measurementsaretakenbymarkingoffa
distanceXalongthecenterpillarfromBtoCandadistanceYalongthe
bodysillfromBtoA. SetthetramwithitsendsonpointsAandCand
comparethislengthwithsimilarpointsontheundamagedsideofthevehicle
or on a similar vehicle. Any misalignment of the door opening will be
indicatedbythenecessityofresettingthetram.
(17) Ifbothsidesofthevehiclearedamaged,layoutarectanglesuch
asABCDwhichisshowninfigure19,inacorrectlyaligneddooropening
ofasimilarvehicle.ThenmeasurethedistanceXandYandtransposethese
measurementstothedooropeningofthedamagedvehicle.IfthediagonalsA
CandBDarenotequal,thedooropeningisoutofalignment.
(18) After the door openings on both sides of the vehicle have been
checked,measurethefrontsectioninthesamemanner.Inthismeasurement,
thesamepoints,AandDasbefore,areusedtogetherwithpointsFandEin
correspondingpositionsontheoppositedooropenings,toformthecorners
of a rectangle (figure 20 on thenextpage). ThediagonalsAEand D F
shouldbeequal.Iftheyarenot,themisalignmentmustbecorrectedbefore
otherchecksaremadeonthebody.
30
METAL BODY REPAIR - D1653 - LESSON 1/TASK 1

FIGURE19.XCHECKINGDOOROPENINGALIGNMENTWITHATRAM.
FIGURE20.CHECKINGFRONTSECTIONALIGNMENT.
31

(19) Becausethefrontsectionislogicallydividedintotworectangles,
oneabovetheinstrumentpanelandonebelow,eachoftheseshouldnextbe
tested separately to determine whether the instrument panel is in line
(figure21). Thistime,pointsGandEarelocatedatcorrespondingtop
hingeboltheadsontheoppositecowlhingepillars.Thetestisnowmade
justasbeforewiththetram,whichthistimeshouldshowdiagonalsEGand
DHtobeequal,andGFandAHtobeequal.
FIGURE21.CHECKINGINSTRUMENTPANELALIGNMENT.
(20) Thecentersectionistestedtwice.FirstpointsIandJ(figure22
on the following page) are located on the opposite door corresponding to
pointsCandBofthedooropeningtest.ThediagonalsBIandCJmustbe
equal. ThenpointsKandLarelocatedatcorrespondinglocationsinthe
middleofthecenterpillar,suchasthepressedmoldinginthebodypanel.
IfthetramshowsBLandJKtobeequal,centeralignmentissatisfactory.
32

FIGURE22.CHECKINGCENTERSECTION
ALIGNMENT.
(21) Thelasttesttobemadeinacoachstylebodyisacheck ofthe

frontsectionagainstthecentersection(figure23).Forthistest,nonew
pointsneedbelocated;thetramismerelyusedtocomparemeasurementAI
andCFandBEagainstDJ.
FIGURE23. CHECKINGALIGNMENTOFTHE
FRONTSECTIONAGAINSTTHE
CENTERSECTION.
33

(22) Tocorrectcollisiondamageinamotorvehicle,itrequiresastrong
forceoppositetothedirectionoftheimpact.Powerfulportablejackshave
been developed to replace crowbars,planksandothermakeshiftsthat were
used for years to force damaged frames and bodies back into shape. The
portablehydraulicjackshowninfigure24iscapableofexertinga10ton
force.Itconsistssimplyofahydrauliccylinderconnectedtoahandpump
through a hose. It is provided with attachments for pushing, pulling,
bending, clamping, or spreading, which can be used singly or in
combinations.
FIGURE24.PORTABLEHYDRAULICJACK.
Before using the jack, size upthejobtodeterminethedirection of the

damagingforce. Iftheframehasbeentwisted,alignthisfirst,removing
thebodyifnecessary. Makeasetupusingtheramanditsattachmentsto
applyhydraulicforce,reversingtheforceofthedamagingimpact.
To operate the jack, insert the handle into the pump beam either
horizontallyorvertically.Closethereleasevalve,turningitbyhandas
faraspossibletotheright.Thedownstrokeofthe
34

handleforcesoilthroughthehosetotheram,causingtheplungertotravel
outwardunderpressure.Toreleasethepressure,turnthereleasevalveon
thesideofthepumptotheleft.
d.
HammerFinishing.
Whenafenderorbodypanelisformed,theshapeofthedieistransferred
tothesheetmetal.Later,ifthepanelbecomesbent,creasesinthepanel
tendtoholditoutofshape. Nevertheless,moststressestransferredto
themetalwhenitwasformedonthebodyarestillinthepanel.Whenthe
stress of the crease is relieved, the panel will return to its original
shapebyitself.Sincethemetalwilltrytoreturntoitsoriginalcontour
of its own accord, it must be determined what is preventing it from
returning. Usually, it will be found that a crease has been formed by
impact. This crease may exist in the panel, or it may be found that a
creaseintheinnerconstructionispreventingthepanelfromreturningto
itsoriginalcontour.Ifthemetalishammeredexcessively,itwillbecome
stretched. For this reason, it is important that each job be approached
withtheideaofrelievingthestrainthatisholdingthedamagedareaout
of position. Light hammer blows will not displace the metal as much as
heavyblows.Severalwellplacedlightblowsaremoreeffectivethanoneor
twohardblows. Eachwelldirectedblowofexactlytherightforceisan
effort toward permitting the metal to attain its original contour. Each
misplacedblow,orablowharderthanrequired,maycreateadditionaldamage
whichmustbecorrected.
(1) DirectHammering.
(a) Smallpimplesmayberemovedbydirecthammering.Figure25and
26 (on the following page) show how the dolly block is held for this
operation,aswellastherelationshipofthehammertothedolly.
(b) Beforeusingthedollyandhammertogether,itwillbenecessary
tocleantheundersideofthatportionofthefenderonwhichworkwillbe
performed.Bodypanelsandsomefendersmaybecoveredwithsounddeadening
material (undercoat) that must be removed prior to dinging. Deadening
materialmaybepadsormatsofafeltmaterialgluedinplace,orheavy,
tarlike,blackmaterial
35
- LESSON 1/TASK 1
that has beenapplied in asemifluidstate. Thismaterialmayhave been

brushedorsprayedonthepanelandlaterdried.Inaddition,theunderside
of fenders,hoods,orbodiesmaybeundercoated. Thisdeadeningmaterial
mustbecleanedfromthemetalbeforeworkingwiththehammeranddolly.
FIGURE25. HOLDINGDOLLYCORRECTLYWHEN
HAMMERINGDIRECTLY.
FIGURE26.
36
POSITIONSOFHAMMERANDDOLLY
WHENDIRECTHAMMERING.

(c) Indirecthammering,thedisplacedmetalwillbepushedbackto
its original contour, by using a dolly that matches the original contour
underthedamageandstrikingthedamagewithahammer.Thedollyprovides
supportandpreventstheundamagedareasfrombeingpushedoutofplace.If
the metal is not struck squarely over the dolly, the metal will have no
support,creatingdamagewhichlatermustbecorrected.
(d) Startbyusinglightblowsthatshowifthemetalisbeingstruck
squarelyoverthedollyblock.Letthedollylayinthehandandgripthe
hammerloosely.Whenthefirstpimplehasbeeneliminated,movetothenext
one,untilallhavebeenremoved.Twothingsoccurwitheachhammerblow:
1 Thehammerboundsofitsownaccord,makingitreadyforthe
nextstroke.
2 The hammer blow ontopwilldrivethedollyblockaway from
thefender;thenormalresiliencyofthearmwillbringitback,strikinga
blowonthemetalfromunderneath.Theseactionsoccurnormallyonlyifthe
hammeranddollyblockareheldloosely.Theimportanceofthisspringback
ofthedollybecomesapparentasshowninindirecthammering.
(2) IndirectHammering.
(a) Metal that has not been excessively hammered, displaced, or
stretchedwillhaveatendencytoreturntoitsoriginalcontourofitsown
accord. Thisisdueto theinternalstressimpartedtothemetalby the
forming dies. If the metal is prevented from springing back by other
strainsimpartedtoitbyadditionalbendsorcreases,themetalisrestored
to normal contour by relieving whatever new stress is holding it out of
position.
(b) In bumping or dinging, this is accomplished by relieving the
stress with indirect hammering. Figure 27 (on the following page)
illustratesacrosssectionofadamagedareainwhichsharpcreaseshave
beenformedallaroundanareaandanothersharpcreasehasbeenformedin
the low spot of the damaged area. The procedure employed in indirect
hammering is to hold a dolly having the correct contour to match the
originalcontourof
37

FIGURE27.POSITIONOFTHEDOLLYWHEN
INDIRECTHAMMERING.
themetalatthelowspot,andtostrikeaseriesoflightblowsaroundthe
outercreases.
(c) Thecorrectiveactionisasfollows:
1 Alightblowwillnotdisplacethesurroundingundamagedarea,
but the force of the blow will be transferred to the dolly block. In
effect,thispushesthebentportiondownwardandstraightensit.
2 Asaresultofreceivingthehammerblowindirectly,thedolly
block will be pushed away from the low part of the damage. However, it
impactsalightpushupwardonthisarea.Knockedawayfromthefender,the
workman'shandwillautomaticallybringitbackinplace,impartingasecond
lightblowtothearea.Asworkprogresses,usinglighthammerblowsaround
theouteredgeofthedamage,thecenterofthedamagedareaslowlyrises
untiltheoriginalcontourisrestored.
(3) SpringHammering.
(a) When acrownisformedinmetal,itbecomesstrongandresists
any change to its shape. It can be compared to an arch used in the
constructionofabuildingorbridge. Thestrengthofthisarchorcrown
can, in many instances, be used to support the surface being hammered
withouttheuseofadolly.Thisiscalledspringhammering.
38

(b) Creasesinmetal,atpointswhereitisimpossibletobackupthe
hammerwithadollyblock,canoftenbecorrectedbythismethod.Totake
advantageofagreateramountofthenaturalsupportprovidedbythecrown
ofthemetal,theforceofthehammerblowisspreadoveralargeareawith
a spoon. Thespoonis placedlengthwiseovertheridgeofthecrease or
otherhighspotandstruckaseriesoflightblowswiththehammeruntilthe
unwantedstressisrelievedandtheraisedportionisbacktoitsoriginal
shapeorposition.
FIGURE28.SPRINGHAMMERINGUSINGASPOON.
(c) In thismethodofhammering,nohammermarksareformed onthe

metal since all of the blows are on the spoon rather than on the metal
(figure 28). Once the metal is back to its original crown, additional
hammering willcausethesurfacetosinkbelowitsoriginalcontourline,
anditmaynotbebroughtbackreadily.Alwaysstartwithlightblowsand,
asthejobnearscompletion,inspectthecontouraftereachblow.Thiswill
reducethepossibilityofsinkingthehammeredsurfacetoolow.
(4) PickHammering.Pickhammeringisoneofthemostdifficultjobsto
master. Youwillneedalotofpracticebeforeyoucanmakecompetentuse
ofthistool.
39

(a) A pick hammer is used to bring up low spots, particularly in
areas which have been badly creased or stretched and have lost their
tendencytoreturntotheirnormalcontour.Figure29illustratesexamples
ofpickhammeringemployedtoraiselowspots.Asarule,thepickhammer,
workingfromtheundersideofthemetal,isusedtohitthecenteroflow
spotsthreeeighthsofaninchorlessindiameter.
FIGURE29.EXAMPLESOFPICKHAMMERING.
(b) Thepick,beingsharp,stretchesthemetalandformsapimpleon
thesurface. Atthesametimethepimpleisformed,themetalimmediately
surroundingit,thoughnotdisplacedorstretched,israised.Itisobvious
thataccuracyintheuseofthepickhammerisoftheutmostimportance.
e.
MetalShrinking.
(1) General.Whenbodypanelsandfendersareformedindiesunderhigh
pressure,thesheetmetalisstretchedanddrawn,thencompressed.This
40

displacesthemoleculesofmetal.Thehighpressureofthepresssqueezing
the metal locks the molecules in a new position. They will resist any
subsequent forcewhichtriestochangetheirarrangement. Metalhassome
elasticity; that is, metal can be bent or twisted without permanent
disarrangement ofthemolecules. Whentheforcethusappliedisremoved,
theelasticityofthemetalwillcauseittoresumetheshapethatithad
whenthemoleculesofthemetalwerelockedtogetherinthedies.Thebody
repairmanmustavoiddestroyingthisnaturaltendencyofthemetaltoreturn
toitsoriginalshape.Thisisnotalwayspossibleincollisionswherethe
normally smoothsurfaceisbadlycreased. Creasesrepresentaportionof
themetalthathasbeendistortedbeyonditselasticlimitandinwhichthe
moleculeshavebeendisplaced. Theyarenolongerlockedtogetherinthe
samearrangementthatwasgiventothemintheformingdie.
(2) HotShrinking.
(a) Hotshrinkingisasimpleprocess,butitrequirescarefultiming
andpropertools. Toolsrequiredarethosewhichareusedformanyother
operations in body work; i.e., a welding torch that is equipped with the
samesizetipasusedforweldingthethicknessofsheetmetalbeingworked
on;abodyhammerormallet;shrinkingdolly;acontainerofwater,anda
spongeorrag.
(b) Arrangethetoolssotheyarewithineasyreach.Itisnecessary
tochangequicklyfromonetooltoanotherwhenperformingshrinkingwork.
(c) Locate the highest point in the stretched section of the panel
withwhichyouareworking.Lightthetorchandheataspotthesizeofa
nickelinthecenterofthehighspot(A)(figure30onthefollowingpage)
toabrightred.Useacircularmotionwhenheatingthespot,beingcareful
nottoburnthroughthemetal.Assoonasthespotisbrightred,placethe
shrinking dolly under the spot and strike it several sharp blows with a
hammerormallet(B).
(d) After driving the center down, hold the dolly block loosely
againsttheundersideofthepanelandexactlycenteredunderthehotspot.
Thehammerblowmusthitthespotaccuratelyandwithsufficientforceto
pushthemetaldownwhileit
41

isstillhot. Afterfourorfivehammerblows,theheatedspotwillturn
black. Quench it immediately withwaterandaragorsponge. Quenching
with water will complete the shrinkingoperation. Repeatthisoperation,
takingthenexthighestspotinthestretchedsectionofthepanel,using
thesequenceshowninfigure31.
FIGURE30.UPSETTINGASTRETCHEDAREA
FORSHRINKING.
FIGURE31.SEQUENCEOFSHRINKINGMETAL.
(e) Incaseofalongnarrowstretchcausedbyasharpobjectrubbing
acrossthesurface,startatoneendandheataspottoabrightred,three
incheslong,inthebottomofthecrease.Whilethespotisbrightred,use
abodyhammertoraisethemetalabovethesurfaceofthepanel.Repeat
42

the above operation until the entire crease has been raised, then shrink
followingtheprocedureasexplainedabove.
(f) When performing a shrinking operation, exercise care to avoid
overshrinkingthepanel.Thiswillcausethemetaltowarpandbuckleboth
inandoutofthestretchedarea. However,ifthisconditiondoesarise,
heat a smallspotinthe areawherethepanelisbuckling,applya dolly
block or spoon with enough pressure to hold the buckling section up, and
allowthemetaltocool.Donotusethehammerorwaterinthisinstance.
In extreme cases, it may become necessary to repeat this operation in
severaldifferentplacesinthewarpedarea.
(g) Aluminum shrinkingfollowsthesamegeneralprocedureassteel.
Care must be used to avoid burningthroughthemetalatpointofcontact
withtheflamebecausethismetalabsorbsheatmuchmorerapidlythansteel
anddoesnotchangecolorunderheat. Caremustbetakenwhenusingwater
as a quenching media because thereisachancethemetalwillcrack when
cooledtooquickly.Justassoonasthemetalstartstoblisterwherethe
flame contacts the metal, the flames must be removed, and hammering done
quicklywithawoodenorfibermallet.
(h) Certain rules should be observed at all times during shrinking
operations.Theyare:
1 Neverquencharedhotspot. Waituntilthemetalhasturned
black.
2 Never heat an area greater than that where pressure can be
appliedatonetimewiththehammeranddolly.
3 Never use anything but an acetylene torch for heating a
stretchedsection.
4 Neverattempttoshrinkapaneluntilitbasbeenroughedout.
5 Neverapplyheattoalowspotforshrinking.Hammeritout,
thenapplythebeat.
6 Ifthestretchedpartofthesurfaceissmall,heatasmaller
spot.
43

7 It is possible to shrink metal without quenching each spot
withwater.However,theshrinkingoperationismuchfasterifeachspotis
quenchedwithwater.Lessheatspotsarerequirediftheheatexpansionis
drawnoutbyquenching,ratherthanbyadditionalspots.
(3) ColdShrinking.
(a) Theshrinkingdollyisformedsothattwosidesofithavealow
crownradius,withthetwoendsbeingconcave.
(b) Thehammerusedistheoffsetcrosspeen. Thehammerissimilar
tootherhammersexceptthatoneendoftheheadisshapedtoexactlyfit
theconcavecontouroftheshrinkingdolly.
(c) After a weld has been made, it sometimes becomes necessary to
sinktheweld. Theconcaveportionofthedollyblockisplaceddirectly
underneath the weld. A blow is then struck with the peen side of the
hammer,drivingthewelddownsothatavalleyisformed. Thisdepression
is made theentire length of theweldedjointandlaterfilledwith body
solderorfiller.
(d) Tocoldshrinkapanel,placetheshrinkingdollyunderthehigh
spotandformaconcavebeadorvalleyaspreviouslyoutlinedinparagraphs
7e(3)(a)through(c)above.Movethedollyalongslowlyinastraightline
beneaththehighspotandstriketheoutsidesurfacewiththehammer.
Do not make the bead any longer or deeper than necessary to draw the
stretchedmetalbacktoitsnormalcontour.Itmaybenecessarytomakean
Xshapedbead.TheXshapedvalleyismadethesamewayasasinglevalley
exceptthatasecondoneismadeatrightanglestothefirstone.
(e) Whenshrinkingaluminum,itmaybebettertocoldshrinkinstead
ofhotshrink.Theprocedureforcoldshrinkingaluminumandsteelarethe
same.
f.
BodyFile.
(1) Abodyfileisusedformanythings:toremovepaint,smoothmetal,
findlowspots,removeexcesssolder,quicklyremovealuminum,andtoform
thecorrectcontourofareasthathavebeenbuilt
44

upwithsolder.Thegageofmetalonsedanbodiesisaslightaspractical,
and every precaution must be taken not to file or grind away any metal
unnecessarily.Whenremovinghighspotsbygrindingorfiling,caremustbe
takennottocutthroughorweakenthepart.
(2) Usingthefileisatwohandjob.Onehandisusedtoholdthe
file handle (figure 32), the other is used to grasp the file around the
saddleattheoppositeendofthehandle.
FIGURE32.BODYFILE.
(a) Thefilebladeisfastenedtotheholderwiththecuttingedges
oftheteethfacingawayfromthehandle. Adjustthecontourofthefile
holdersothatitalmost,butnotquite,matchesthecontourofthesurface.
45

(b) Place the file on the work. With a straight stroke, push the
fileawayfromyou,holdingitatanangleof30degreesinrelationtoits
lineoftravel.Ifthefiledigsin,youareputtingtoomuchpressureon
it. Attheendofthefirststroke,raisethefileandbringitbackto
whereyoustartedandmakeasecondstroke.Remembertoraisethefileat
theendofeachstroke.Itshouldnotbepulledbackoverthemetalbecause
draggingwilltendtodullthefileblade.
(c) By filingintheabovemanner,thefilemarksareparalleland
haveremovedallofthepaint,andprobablysomeofthemetal,fromthework
inthefiledarea.Thistypeoffilingisreferredtoaslinefiling.The
term"linefiling"meansallthestrokes,andconsequently,allofthefile
marks,areinthesamedirection.
(d) Nowchangethedirectionofyourfilestrokessotheyareabouta
45 degree angle from the previous direction. This is referred to as X
filing.WhenthefileismovedsothatyouareXfiling,youmayfindthat
thecontouroftheareadiffersslightly.Ifthisistrue,adjustthefile
holderagaintonearly,butnotquite,matchthecontour.Thengooverthe
entireareaoncelightly. Youwillnowfindthatthenewfilemarkscross
theoriginalfilemarksata45degreeangleandthatthesetwosetsoffile
marks form a series of innumerable X's from which the term "Xfiling" is
derived. Xfilingorcrossfilingisnecessarytoestablishormaintaina
contourthatcurvesinmorethanonedirection;whereas,linefilingisused
onmoresimplesurfaces. Whenfiling,itisalwaysagoodplantomakea
fewcrossorXstrokesoccasionallytomakesurethatyouarenotdestroying
a secondary contour in the metal. This is particularly important when
filingareasthathavebeenbuiltupwithsolderorothermaterial.
(3) Whenusingbodyfilesonepoxyfillers,ensurethatthefillersare
thoroughlycuredorthefilewillclogandgougethesurface.
8.
Conclusion
Knowledge ofthe metal body repairproceduresdescribedinthissubcourse

taskshouldprovideastrongbasisforbeingabletoperformrepairon
46

the various vehicles and trucksintheU.S.Armyinventory. Most of the
repair procedures for collision work involve removal and installation of
various body parts, panels, and accessories. Some require complete
disassemblybeforerepaircanproperlybeperformed.Aspreviouslystated,
withoutaclearunderstandingofthebasicsofautomobileconstructionand
assemblyitisverydifficulttofollowcorrectrepairprocedures. Inthe
next lesson, you will learn the specific repair procedures for repairing
glass,radiators,andfueltanks.
47
METAL BODY REPAIR - OD1653 - LESSON 1/PE 1

PRACTICALEXERCISE1
1.
Instructions
Readthescenarioandrespondtotherequirementsthatfollowthescenario.
2.
Scenario
You have been assigned to an Intermediate Direct Support (IDS) unit just
outside Frankfurt, Germany. For one of your functions in this unit, you
serveastheofficerinchargeoftheservicesection.
A report of survey has just been completed on a military sedan that was
involved in a collision. Due to a shortage of vehicles within this
particularuserunit,thedecisionwasmadetorepairtheautomobileinstead
ofapplyingcodeHtothevehicle.
Though youareintheprocessofreceivingadditionalbodyrepairmen,you
findoutthatthesemenarefromareserveunit. Beforeassigninganyof
the reservists to work on the damaged sedan, you decide to test them on
variousoperationsrequiredtorepairadamagedvehicle.
3.
FirstRequirement
Using your knowledge of metal body repair and this subcourse, prepare an
answer sheet for the questions listed below regarding the procedures
requiredtorepairdamagedvehicles.
a.
Whydopassengercarandtruckbodiesdifferinconstruction?
b. Whatbodypanelassemblyisusuallythelargestvehiclepanel,andalso
thesimplestinconstruction?
c.
Whatisadecklidcommonlycalled?
d.
Whatstocksareautomotiveframesusuallyconstructedfrom?
e. What are the two most common tools used to remove paint, rust, and
undercoating?
48

f.
Describea"drop"frame.
g. Isiteconomicaltorepairabodywhichhassustaineddamagetothemain
structuralmemberssevereenoughtocollapsetheboxsectionmember?
h. WhatitemisNOTrecommendedasanaidinstraighteningcrossmembers:C
clamps,heat,hydraulicjack,orattachments.
i. Whatistheprimaryreasonrivetsareusedtoconnectseparatepartsof
automobileandtruckframes?
j.
Whatvehiclehardwareisnormallyreferredtoastrim?
k. Weatherstrippingisnormallyusedtosecurewindshieldglasswithinthe
roofpanelassembly. Howarethewindshieldsofcombattypevehiclesheld
inplace?
l. Adinginghammerisageneralpurposehammerprincipallyusedonwhat
automotivepanel?
m.
Namethehammerthatisusedtoraisesmall,lowspotswhencrossfiling.
n.
Describetheshapeofaroughinghammer.
o.
Whatalloyisthehighcrowndollymadefrom?
p. On what parts of the vehicle will the hooks on the low crown dolly
normallybeused?
q. What tool is used for removing dents on quarter panels around rear
pillars,behindinnerconstruction,andbehindbackpanelstrainers?
r.
Whatisanothernameforacaulkingiron?
s.
Namethetwotypesofhydraulicbodyjacks.
t. Whathydraulicjackcomponentgives6inchesofpromptadjustmentwhen
pushingoutlargeareas.
u. Five different minerals are commonly used for manufacturing abrasives
usedwithsandingdisks.Nametheseabrasives.
v. NamethebodyshopapplicationsforusingaclosecoatNo.36sanding
disk.
49
METAL BODY REPAIR - OD1653 - LESSON 1/PR 1

w. WhatsandingdiskisusedtoremovescratchesleftbyNo.24andNo.36
sandingdisks?
x. Restoring vehicle body panels of sheet metal to their normal contour
aftertheyhavebeendamagedisnormallyreferredtoaswhat?
y. When using a dolly, what is lost if it is gripped tightly or held
againstthebodypanelwithagreatamountofpressure?
z. Whatisthemeasuringdevicewhichisatelescopingtubeequippedwith
anextensionclampwhichfixesitasthemeasurementofonediagonalismade
forcomparisonwithanother?
aa. Whenthestressofacreaseinabodypanelisrelieved,isitnormal
forthepaneltoreturntoitsoriginalshapebyitself?
bb. When hammer finishing, are several well placed light blows more
effectivethanoneortwohardblows?
cc. Beforeusingadollyandhammertogethertocorrectdamagetoafender,
whatmustbedonefirst?
dd. Namethetoolsnormallyusedwhenperforminghotshrinkingofmetal.
ee. Aluminum shrinking follows the same general procedures as steel.
However,caremustbeexercisedtoavoidburningthroughthealuminum.Why
isiteasiertoburnthroughaluminumthansteel?
ff. Asageneralrule,aredhotspotshouldnotbequenched. Whenisit
safetoquenchahotspot?
gg. As a general rule, is it correct to apply heat to a low spot for
shrinking?
hh. Namethehammerthatismostoftenusedwhenperformingcoldshrinking
operations.
ii. Whenshrinkingaluminum,whichisthebetterprocess:coldshrinkingor
hotshrinking?
jj. Whenusingbodyfilesonepoxyfillers,whyisitnecessarytoensure
thattheyarethoroughlycured?
50

kk. Whatisthepurposeoftinningametalsurface?
ll. Beforeasolderpaddleisappliedtohotsolder,itshouldbecovered
withwhattopreventthehotsolderfromstickingtoit?
mm. Whenusing30/70solderinapaddlesolderingoperation,whatdothese
numbersrepresent?
51

LESSON1.PRACTICALEXERCISEANSWERS
1.
FirstRequirement
a.
Thepurposethateachisintendedtobeusedforisdifferent.
b.
Theroofpanelassembly.
c.
Trunk.
d.
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
Channelstock
Angle
Tstock
Zstock
Tubing
Ibeam
Flatplates
Acombinationofanytwoormoreoftheabovestocks
e.
(1)
(2)
Wirebrush
Grindingwheel
f.
Themainpartorcenteroftheframeisdroppeddownbetweenthefront
andrearwheels.
g.
No.
h.
Beat.
i.
Rivetsareusedbecauseoftheirstructuralstrengthandtheirability
togivewiththeroadcondition.
j.
(1)
(2)
(3)
(4)
(5)
(6)
k.
Combattypevehiclewindshieldsareheldtogetherbyametalframeand
sheetmetalandmachinescrews,andareattachedtothebodybyhinges
andbrackets.
l.
Bodypanels.
m.
Pickhammer.
52
Moldings
Floormats
Armrests
Headlinings
Doortrimpads
Weatherstripping

n.
Acurvedshankwitharoundface.
o.
Forgedalloysteel.
p.
(1)
(2)
(3)
q.
Doubleendandlowerbackquarterpanelspoon.
r.
Fenderbeadingtool.
s.
(1)
(2)
t.
Sliplockextension.
u.
(1)
(2)
(3)
(4
(5)
Garnet
Flint
Emery
Aluminumoxide
Siliconcarbide
v.
(1)
(2)
Removingwelds
Revealinghighandlowspotsinbumpingoperations
w.
ClosecoatNo.50.
x.
Metalbumpingordinging.
y.
Automaticbounceandreboundofthedolly.
z.
Thetram.
aa.
Yes.
bb.
Yes.
cc.
The underside portion of the fender being worked on must first be

cleaned.
dd.
(1)
(2)
(3)
(4)
(5)
ee.
Aluminumabsorbsheatfarmorerapidlythensteelanddoesnotchange
colorunderheat.
ff.
Whenthemetalhotspothasturnedblack.
Fenderbeads
Dripmoldings
Sharp,concavedmoldings
Directactingjack
Remotecontrolledjack
Weldingtorch
Abodyhammerormallet
Shrinkingdolly
Containerofwater
Ragorsponge
53

gg.
No.Itshouldbehammeredoutbeforeheatisapplied.
hh.
Offsetcrosspeen.
ii.
Coldshrinking.
jj.
If the epoxy has not thoroughly cured, the body file will clog and
gougethesurfacebeingworkedon.
kk.
The process of tinning prepares a surface for receiving and holding

solder.
ll.
Alightcoatofoil.
mm.
Soldercomposedof30percenttinand70percentlead.
54

LESSON2
OPERATIONSREQUIREDFOR
GLASS,RADIATOR,ANDFUELTANKREPAIR
TASK1. Describetheoperationsrequiredforproperglassrepair.
CONDITIONS
assistance.
STANDARDS
Withinonehour
REFERENCES
1.
Introduction
The many glass sections found in modern vehicles are meant to give the
driverandpassengersaclearviewofthetrafficandsurroundings. Itis
hazardoustodriveavehiclewhichhascrackedorfoggedglass. Brokenor
faulty glass not only obstructs visibility, but sudden fragmentation may
cause serious injury to the car's occupants. Cracked and broken glass
sections are very common, and the auto body technician will encounter
replacementjobsoften.
The glass used in automobiles differs greatly from conventional types of
glass.Automotiveglassmustfurnishclear,undistortedvisibilityaswell
as meet certain safety standards. The visibility feature of auto glass
refers to freedom from distortion. The glass must furnish a clear and
unobstructed view from all angles. Making such glass requires special
technology andveryclosetolerances. Theearlyautomobilesdidnothave
suchglass,andpoorvisibilitywasoftenacauseofaccidents.
55

2.
GlassCompositionandCharacteristics
Glass at ordinary temperatures is rigid, not easily corroded except by

hydrofluoricacid,andiscomparativelyresistanttoabrasion.Likewax,it
becomessofterandmorepliableasthetemperaturerises.Saltwaterhasa
chemicalorabrasiveactiononglassthatcausesafrostedappearanceafter
sufficient exposure. It is only slightly porous and, therefore, easily
cleaned.Glassisnotentirelycolorless.Theabilityofglasstotransmit
lightandofferprotectionagainstair,water,anddustmakesglassoneof
themostimportantautomotivematerials.Glassisonlyslightlylessstrong
than some grades of cast iron. But, it is far more brittle, and any
externalforcewillsetupstresseswithinitthatwillberetainedforsome
time. Anyforceaddedtotheseretainedstressesmaycauseabreak. This
propertyisagreataidincuttingsheetglass.Glassismadebycombining
a silicate such as common sand, and alkali such as sodium carbonate, and
eitherleadorlime.Itiscommonlyclassifiedasleadglassorlimeglass.
a. LeadClass. Thisglasshasthehigherlusterbutismorebrittleand
more easilyscratched. Itisusedprincipallyforopticalanddecorative
purposes.
b. LimeGlass. Onlylimeglassisusedforautomotivework.Becausethe
availablesupplyofsilicate,alkali,andleadorlimeisnotusuallypure
or readily usable, carbon, arsenic or other substances must be added to
purifythemandassistthemincombining.Substancessuchasiron,copper,
or chromium may also be added to change the color, hardness, or other
properties. These solid components, melted together, form liquid glass.
Whenitsimpuritiesrisetothesurface,themoltenglassisdrawnoffand
allowedtoharden.Asheetofglassisgenerallyalarge,flatpiecehaving
noparticularshape.Whenthetermisappliedtolaminatedglass,itmeans
oneofthelayers.Laminatedglassissoldincut,rectangularsheetsfrom
4by18to24by56inches,calledblocks.About50squarefeet,weighing
approximately200pounds,areordinarilypackedtogetherandareknownasa
box.
56

c.
TypesofGlass.
(1) PlateGlass.Plateglassispouredonaflatheatedsurface,cooled
until it becomes plastic, and then rolled to about twice the thickness
intended for the finished plate. After rolling, it is slowly cooled or
annealed,andwhencolditisgroundwithsandandpolishedsmoothandflat.
Modernglassmakingisacontinuousprocessinwhichglasscomesoutbetween
rollersinacontinuousribbon.Theribbonisnotcutuntilitiscoldand
readyforgrinding.Grindingandpolishingmakethesurfacemoreporousand
less resistant to attack by acids, alkalies, and (of special importance)
salt water. It must be handled carefully and kept clean; crayon marks
imbedded in its pores cannot be completely removed. Plate glass may be
temperedtomakeitharderandmoreshockresistant.
(2) WindowGlass. Windowglassisblownorpouredintosheetsofthe
desiredthickness,thenannealedandcuttothedesiredsize.Unlikeplate
glass,itisnevergroundorpolished. Thesurfacethereforeissomewhat
lessporousthanplateglassandmoreresistanttoscratchesandsaltwater,
butitisslightlywavy.Likeplateglass,itmaybetempered.Testsshow
thatplateglassismarkedlysuperiortowindowglassinmotorvehiclesfor
reducingfatigueandeyestrainandincreasingtheabilitytojudgedistance
andtoreadroadsigns.
(3) TemperedGlass.Temperedglassismadebyreheatingplateorwindow
glassuntilitissomewhatsoft,andcoolingitquicklyinabathofhotoil
oragainstacoldmetallicsurface. Itwillthenwithstandheavyimpacts
and great pressures. However, a comparatively light blow with a pointed
objectwillbreakitbecauseoftheinternalstressescausedbythesudden
cooling, and it may fly apart violently when broken. Because of these
internal stresses, it cannot be cut or ground, but is shaped when soft.
Rearwindows,particularlycurvedones,maybetemperedglass.
(4) BulletproofGlass.Bulletproofglasshasverylimiteduses.Itis
verythick,usually3/4inch,andresistsbullets.Theymay,however,chip
orcrackit.Bulletproofglassandcurvedglass,
57

whichareseldomusedbytheArmy,arenotordinarilycutexceptinshops
especiallyequippedforthatpurpose.
(5) LaminatedSafetyClass. Glassthatbreaksintosmall,sharppieces
is dangerous to use for windows in motor vehicles. Manufacturers have
therefore developed laminated safety glass, which is built up like a
sandwichwithasheetoftoughplasticmaterialbondedbetweentwosheetsof
glass. Ifthisglassbreaks,theplasticstretcheswhenhit,servingasa
cushionandholdingthesharpglassfragmentsfirmly.Exceptforitssafety
feature, laminatedsafetyglasshasthesamepropertiesastheglassfrom
whichitwasmade.Itisusedforreplacementofpracticallyallflatglass
inArmymotorvehicles,suchaswindowsandwindshields.
d. RemovalofVehicleGlass. Whenremovingbrokenglass,carelessnesscan
resultincutsfromsharpedgesorflyingparticlesofglass. Bycareful
removal,theoldglasscanbeusedasapatternforthecuttingofnewglass
forthevehicle. Themethodofremovingglasswillvaryaccordingtothe
make and model of the vehicle. All Army combattype vehicles have
windshieldanddoorglassenclosedinprotectingmetalchannelsorframes.
(1) Combattype vehicles (3/4 ton and larger) windshield hinges are
composedofarolledstripattachedtotheundersideofthetopoftheouter
windshieldframeandasimilarrollontopoftheindividualmetalframeof
thewindshield. Toseparatethem(whenthewindshieldisopen),slidethe
entiremetalframeofthewindshieldglasssidewaysoffthevehicle. They
arereinstalledinthereverseorder.
(2) Glass that is installed in channels or frames is removed with a
channelvise. Thevisehasrubberpaddedjawstoholdtheglasssecurely
andanadjustablelevertopullthechannelfromtheglasswithoutcracking
orbreakingtheglass. Carefulremovalofoldglassisthebestsourceof
obtainingaccuratepatterns. Itisnecessarytohavepatternswhereglass
installationisconcerned. Afterapatternismade,itshouldbeplainly
markedaccordingtomakeandmodelandkeptforfurtheruse.
58

e. GlassCutting. Glasscuttingisdividedintothreeoperations. They
are:makingthecut,crackingthecut,andcuttingormeltingtheplastic.
The first two are the most difficult, since they consist of setting up
stressesintheglasstoguidethecrackandapplyingforcesthatcauseit
tobreakalongthelineofthesestresses.Anyotherstressesmaycausethe
crack to travel away from the desired line. Stresses can be set up by
supportingtheglassonanunevensurfaceorbyapplyingpressuretoanedge
orcornerwhichisunsupported.
(1) A cutting bench made of wood or steel can be used as a support.
Plywoodisanidealtopforacuttingbench.Thebenchmustbecoveredwith
aclothcoverwhichissoftenoughtopreventscratching,yethardenoughto
supporttheglassrigidly. Thetopofthebenchshouldbelargerthanthe
largest piece of glass to be cut. For a shop that does much cutting, a
revolving pattern table is ideal. With a revolving top, the workman can
standinonepositionwhilecuttingadoorglass.Ashecomestoacurvein
the pattern,herotatesthetable,eliminatingtheneedformovingaround
andvaryingthecut.Smoothercutscanbemadeanditiseasiertogetthe
topcutdirectlyabovetheinnercut. Thecuttingbenchshouldbelocated
wherethetemperatureisthemostconstant.Suddentemperaturechangeswill
almostcertainlyresultinbreakageoftheglass;therefore,thebenchmust
notbelocatedwheredraftswilloccur.
(2) Glass should be stored vertically in bins. Each size should be
storedinaseparatebinandlabeled.Asheetofpaperplacedbetweeneach
sheetofglasswillpreventscratchingofthesurface.
(3) Ahardwoodruler,widerandthickerthananordinaryyardstickand
usually60incheslong,isusedasastraightedgeandmeasuringdevice. A
small flange at one end may be hooked over an edge to eliminate the
necessityofholdingthatend.Thisrulerismarkedineighthsofaninch.
(4) Thecommonglasscutterhasasharp,hardenedsteelwheelmountedon
apininasteelorwoodhandle.Handlesvaryinsizeandlengthaccording
torequirements.Theycanbeprocuredinthesingleormultiplewheeltype.
Diamondtipcuttersarealsousedbylargeorganizationswhere
59

alltypesofglassarehandled. Thewheeltypeisbestsuitedforcutting
laminatedsafetyglass. Tokeepthecutteringoodconditionwhennotin
use,immerseitinamixtureofkeroseneandoil. Thismixturekeepsthe
cuttercleanandallowsthewheeltoturnfreelyonitsshaftatalltimes.
When cutting glass, first make sure it is thoroughly cleaned. The glass
surfaceshouldfirstbewipedaroundthecuttinglinewithkerosene. This
servesasasolventandcleansthecuttingareaofgrease,oilstains,and
other contaminants. The kerosene will also help eliminate much of the
flakingfromthecut.
(5) Holdthecutterbetweentheindexandsecondfingers. Thisholds
thecutterfirmly,andthereisnotendencyforittorockbackandforthas
pressureisapplied.Letthelastthreefingersofthecuttinghandreston
theglasswhichisbeingcutoronthesurfaceofthecuttingtable.This
willsteadythehandandincreaseaccuracy.Itisalsolesstiring.
(6) Makecertainthattheglasshasbeenwarmedbeforecutting. Glass
ismucheasiertocutandlesslikelytobreakwhenwarm.Ifglassistaken
fromacoldroom,placeitnearawarmstoveorwarmradiatorfor5to10
minutes beforeitiscut. Whencutting,donotpresshardonthe glass.
Forbestresults,exertjustenoughpressuretomakeafinelinecut. Too
muchpressurecausesflakingandmaydestroythecut.Chipsareoftenminor
runs,butmaybecomecracksintheglasslateron.Theglassshouldbecut
theexactsizeofthepatternandfinished1/32ofaninchsmaller. This
enablestheglasstohaveampleroombetweentheglassruns.Pushorpull
thecutter.Infollowingastraightedgeorapatternthickenoughtoserve
asaguideforthecutter,itisbettertopullthecutter.However,when
youmustguidethecutterbywatchingapatternplacedundertheglass,you
will find it easier to push the cutter. This enables you to follow the
patternwithouthavingthecutteritselfhidingit.Incuttingcombination
safetyglass,itisbesttocuttheheavyglassfirst,makingcertainthat
yourunitclearthroughitsthickness.Thencutandrunthethinnerglass.
(7) Aftermakingthecut,itmustbecrackedimmediatelyorthecutwill
heal,makingthecrackingoperationdifficultifnotimpossible.
60

(8) Laminatedsafetyglassmustbecutandcrackedoneachside. When
makingthecutontheoppositeside,thepatternmayberemoved.Thecutis
thenmadeontheothersidedirectlyoverthefirstcut.
(9) Thefollowingstepsshouldbetakenwhencuttingcurvedwindshields:
(a) Theoutboardlight(outerlayer)shouldalwaysbecutfirst.To
cut theinboardlight(innerlayer),turnthecurvedwindshieldoverwith
theoutboardlightfacingthetable.Beforecutting,supportbothsidesof
thecurvedwindshieldtopreventsagging.
(b) A windshield body opening improperly aligned after an accident
requiresspecialcareintrimmingglassforreplacement.
(c) After making the score, or cut, use glass pliers with several
thicknessesofclothbetweenthejaws.Thiswilldistributethepressureto
theradiusoftheglass. Withalittlepractice,itwillbefoundthata
curvedwindshieldisaseasytocutasflatsafetyglass.
f. PlasticCutting.Whencuttingtheplasticbetweenthesheetsofglass,
thefollowingproceduresshouldbeobserved:
(1) Afterthecuthasbeenmadeandcracked,itwillbecomenecessaryto
heattheplasticsothatitcanbecutorseparatedfromthetwopiecesof
glass.Thiscanbedonebyoneofthefollowingmethods:
(2) A tankor vat of hot (notboiling)waterintowhichthepieceof
glasscanbeimmersedandleftforashorttime(2minutes)willcausethe
plastictomelt(donotplacecoldglassinhotwater).Allowtheglassto
reachroomtemperature(70degreesF)beforedipping.
(3) Anyliquidwhichwilldissolveplasticmaybeusedtodissolvethe
plasticbetweensafetyglasssheets. Methanol(alcohol)hasbeenfoundto
bebest.Afterbothsidesoftheglasshavebeencutandcracked,methanol
ispouredorsquirted
61

intothecrackandlefttosetforapproximatelytwoorthreeminutes. A
slightpressuredownwardisapplied,separatingthetwopiecesofglass.
(4) Inthehotwiremethod,acoilofwire1/4inchindiameterand72
incheslong(thewireis1/16inchindiameter)isheatedelectrically.It
islaidalongthecrackandcoveredwithnotchedasbestosandleadweights.
Oneleadfromthe110voltcircuitswitchispermanentlyconnectedtoone
endofthewire.Theotherleadisattachedbyacliptoaselectedpoint
onthewireandtheswitchturnedon,heatingthewiretoabrightred.The
heatedplasticsoftensandthewasteglassdropsfromitsownweight.Waste
pieceslessthananinchwidemayhavetoberemovedwithglasspliers.
(5) Common difficulties in the hot wire method are: bubbling in the
plastic,causedbytoohotawireortoolongaheatingtime;separationof
glass sheets along the edge of the cut, caused by stretching the plastic
excessively;andchippingalongthecut,causedbybendingthewastestrip
upanddown,ratherthanpullingitstraightout.
g. GlassGrindingandFinishing. Thegrindingmachineisequippedwitha
chute which is set so the silicon carbide abrasives flowing onto the
roughingwheelwillhitthewheelattheedgeoftherecess.Placeasmall
quantity of silicon carbide grains in the chute and saturate them with
water.Thenletacontinuoustrickleofwaterrunontothegrainstocarry
asufficientamountofgrainsontothefaceofthewheel. Thecornersof
theglassshouldnotbecuttooclosetotheoutlineofthepattern.Amore
accuratefitcanbemadebyusingthegrindingwheelorbeltedgeroncurved
surfaces.
h. Grinding.Thesiliconcarbideabrasivegrainsdothecutting(grinding)
and can be reused. New silicon carbide should be added at the ratio of
about two pounds to each 1000 inches of glass beveled. Before reusing
carbideormixingwithnewcarbide,itisadvisabletowashtheoldcarbide
toremoveallforeignmatter. Thisforeignmattershouldthenbestrained
throughordinarywindowscreentoremoveanylargechipsofglass.
62

(1) Topreventtheabrasivegrainsfromthecastironwheelbeingflung
over the shop area, it is suggested that a rubber inner tube be tacked
around the inside of the roughing box (about onehalf inch above the
roughing wheel). This allows free passage of glass beyond edges of the
roughingboxforworkingedgesofbevelswithoutinterference.
(2) If glass is to be rough ground oily, seam or chamfer both sharp
edgesfirst;thenrunglassacrossthewheelfromlefttoright,holdingthe
glassperfectlyverticalifaflatedgeisdesired.Donotseamorchamfer
the edge first, but simply roll the glass back and forth as it is being
drawnfromlefttoright,fromanangleofabout45degreesawayfromyouto
straightup.Donotrolltheglassallthewaytowardtheoperatorasthis
willchiptheglassedge.Whenroundedononeside,turntheglassaround
and repeat the operation. Use the full face of the wheel to prevent
grinding grooves in the face. Whengroovesforminthewheel,the wheel
shouldbereplaced.
i.
InstallingGlass.
(1) Glass, in terms of its installation, is either stationary (the

windshield, some quarter windows, and the rear window) or it is moveable
(doorwindow,tailgatewindowandsomequarterwindows).Inadditiontothe
customarycareonemusttakewhenhandlingglass,toprotectitfromimpact,
there are several general precautionswhichshouldbeobservedwhenever a
replacementistobemade.
(a) CheckParts.Becertainthatthereplacementpartisthecorrect
part.Thesizeandcontouroftheglassmustbeanexactfitintheopening
intowhichitistobeinstalled.Thus,itpaystotakethetimetoverify
thepiecebeforestartingthejob.
(b) Use Protective Covers. Over all adjacent body surfaces, to
minimize cleanup and avoid damage to paint finishes and fabrics, use a
cover. These covers may also serve as a protection against chipping the
glassorotherwisedamagingtheedges.
(c) InspectHardware.Inspectforbendsorobstructionsinthepinch
weldflanges,glassrunchannels,frames,regulators,orwhatevercomponents
maybeinvolvedinholdingormovingthe
63

glass.Anyindicationofdamageshouldbecorrectedbeforethereplacement
glassisinstalled,includingdentsinthebodywherethehardwarefits.
(2) WindshieldRemovalandInstallation,Truck1/4ton.
(a) Removewindshieldweatherstripfiller(figure33).
FIGURE33.EXPLODEDVIEWOF1/4TONWINDSHIELD.
(b) Aftertheouterweatherstripfillerhasbeenremoved,removethe
glassfromtheweatherstrip.Caremustbetakentoavoidinjuryfromsharp
edgesiftheglasshasbeenbroken.
(c) Inspectthewindshieldframeassemblyfordents,distortion,and
brokenconditions.
64

(d) Replacetheweatherstripassembly,glassweatherstrip,andouter
weatherstrip filler if they are deteriorated, hardened, or excessively
damaged.
(e) To replace windshield glass, soap flange of frame with liquid
soapandinstallglassweatherstripovertheflangeofthewindshieldframe.
Positionthewindshieldglassintheupperleftcorneroftheweatherstrip.
Continueguidingtheglassinplaceintheweatherstrip,usingascrewdriver
to slip the upper portion of weatherstrip over the glass. Position the
windshieldglasssothetradenamereadsrightsideup.
(f) To make the installation of the glass weatherstrip fillers
easier,dipthestripsintoasolutionofsoapywater.
(g) Inserttheendoftheweatherstripfillerthroughtheloopendof
the tool and,using ascrewdriver,inserttheendofthefillerinto the
weatherstripattheupperright.Whentheendofthefillerstriphasbeen
pressedin,proceedtopullthetoolaroundthewindshielduntiltheentire
striphasbeeninserted.
(3) Truck,3/4,21/2,and5Ton.
(a) Remove the four round head screws, four lockwashers, and four
hexagon plain nuts holding inner frame upper left and right crosspieces.
Remove crosspieces with attached inner corner plugs. Spread each inner
framesideandbottomframejustenoughtoloosensafetyglassandremove.
Discardoldtape.
(b) Inspect the windshield frame assembly for cracks or damage to
inner or outer frame or damaged or loose adjusting arms. Replace any
irreparableparts.
(c) To install new glass, place tape on the glass and secure with
masking tape. Oil glass channels and slide the glass and tape into the
channel.Whenfinished,theoilwillcausetapetoswell,therebymakinga
watertightseal.Reinstallthetopcrosspieceandreplacethescrews.
(4) Safety Precautions. Glass handlingOperation can bevery arduous
unlesscertainsafety
65

procedures are strictly adhered to. The following precautions are
recommended:
(a) Alwayswearsafetygogglesandglovesoftheapprovedtypewhenever
youarehandlingbrokenglass.
(b) Discard any removed broken glass in a proper manner. A separate
trashcanforbrokenglassisrecommended. Itscontentsshouldbeclearly
marked.Neverallowscatteredbrokenglassintheimmediateworkarea.
(c) Adviseotherworkersorbystandersintheareaofsafetyprecautions
beforeattemptingtoremovebrokenglass.
(d) Never use compressed air to blow away fragments of broken glass.
Small fragments of glass can become embedded in the skin. A shop
(industrial type) vacuum cleaner should be used to remove fragments of
brokenglass.Ifavacuumcleanerisnotavailable,anoilsoakedragaids
inpickingupsmallfragmentsofbrokenglass.
(e) Removed glass, which is to be reinstalled, should be stored in a
safeplace. Aspecialstoragearea,awayfromtheworkarea,willprevent
accidentalbreakage.
(f) Neveruseexcessiveheatnearanypartoftheautobodywherethere
isglass.
(g) Grindingordrillingglassisaspecializedoccupation. Itshould
never be attempted by persons who are not familiar with the proper
procedure.
3.
Conclusion
This task introduced the specific operations required to repair glass,

including safetyprecautionstofollowwhenworkingwithglass. Thenext
taskwillfocusonprocedurestobefollowedinordertorepairradiators.
66

LESSON2
TASK2. Describetheoperationsrequiredforproperradiatorrepair.
CONDITIONS
assistance.
STANDARDS
Withinonehour
REFERENCES
1.
Introduction
The radiator of a motor vehicle is an essential element of the cooling

system. It must function correctly if the engine is to escape serious
damage fromoverheating. Anengineiscooledbycirculatingwaterwhich
passesthroughthecylinderblock.Itdrawsouttheheatandthenreleases
it to the air while flowing through the radiator. Therefore, if this
circulation is hindered or the water leaks from the radiator, immediate
repairs must be made to protect the engine. Most radiator failures are
caused by vibration, freezing, disintegration, strain, or collision. In
tubularcores,wornorfrozentubes,brokensolderbetweentubesandheader
plates,andcrackedheaderplatesarethemostfrequentcausesoftrouble.
Honeycombcoresusuallyleakintheseamsateitherthesolderedoffsetsor
theheaderstrips. Tankleaksarefew,buttheymayappearatunsoldered
joints,crackedorwornspots,orfittings.
67

a.
RadiatorConstruction.
Automobile,truck,andtractorradiatorsconsistoftwowatertanks(upper
andlower)joinedbyacorewhichdoestheactualcooling.Waterfromthe
cylinder block usually enters the upper tank through the inlet, flows
through thecore,andleavesbythelowertank. Anoverflowpipein the
uppertankcarriesawayexcesssteamorwater. Intheradiatorassembly,
castmetaltanksareboltedtothesidemembers.Gasketsbetweenthetanks
and core make a watertight connection. This type of rigid radiator
constructionisusuallyusedonheavydutytrucksandtractors. Figure34
illustrates stamped metal radiatorsthatareformedbysolderingdrawn or
stampedmetaltankstotheradiatorcore. Thesidemembersarestrapsof
steelsolderedtoupperandlowertanks.
FIGURE34.STAMPEDMETALRADIATOR.
68

This lighter construction has generally replaced the cast metal type in
passengercarsandlightdutytrucks,whereitisusuallyconcealedbythe
hoodandradiatorgrill.
(1) WaterTanks. Almostallradiatortanksarecastorstampedinone
piecetoreducethenumberofpotentialleaks.Abaffleplateintheupper
tank, below the neck, eliminates excessive splashing and distributes the
wateruniformlyoverthetank.
(2) Radiator Fittings. Theradiatorfittingsarethefillerneckand
inletconnectionoftheuppertankandtheoutletconnectionanddrainvalve
ofthelowertank.Thesearemadeofmalleableironorpressedmetal.When
theyaremanufacturedasseparateparts,theyarebrazed,soldered,bolted,
orrivetedtothetanks.
(3) TubularCore. Thistypeismadeofmanyverticaltubes(drawnor
seam welded) soldered through thin sheets of metal at the top and bottom
(calledheaderplates).Theheaderplatesformmountingpadsfortheupper
andlowertanksandblockpassageofwaterfromthetankstothecoreexcept
throughthetubes. Thetubesaregenerallyspacedabout3/4inchesapart,
in two to four straight or staggered rows approximately 1/2 inch apart
(figure35onthefollowingpage).Inastaggeredrow,twiceasmanytube
rows are exposed to the air entering the radiator, which increases the
cooling capacity. Round tubes are easily broken by the expansion of
freezingwater,whereasovaltubeswillbedistortedtosomeextentbefore
breaking.Theradiatingsurfacesofthesetubesareoccasionallyincreased
byspiralfinsoneachtubeor,muchmorecommonly,bythinsheetsofmetal
(horizontal fins) extending all the way across the radiator, 1/8 inch to
3/16 inch apart, in contact with each tube. The front edges of the
horizontalfinsareusuallycrimpedorbentbacktoadoublethicknesswhich
strengthens the radiator core. In most radiator cores, the fins are
solderedtothetubestospeedtheheattransfer. Atubularcoreradiator
is generally larger than a honeycomb core radiator with the same cooling
capacity.
69

FIGURE35.RADIATORCONSTRUCTION
(4) HoneycombCore.Oneformofthehoneycombcorehasslotlikewater
passages extending vertically through the core between sections of honey
likeaircoils.Eachsectionhasanoffsetstampedmetalribbonaroundthe
outside and bent fins within. Adjacent sections are soldered at the
offsets, which are about 1/4 inchwideandextendabout1/4inchin from
eachfaceofthecore. Theribbonatthetopofasectioniscalledthe
headerstrip.Theseribbonsareoverlapped,formingaseam,toconstructa
singletubeorsection. Notethatthisseam,extendingfromthecenterof
the header strip downward to span the side walls of three entire cells,
providesabroadcontactareatosealtheribbons.Somanydifferentshaped
aircellshavebeenusedinhoneycombconstructionthatitisimpracticable
to discuss them all. After learning to recognize a few representative
types,therepairmanshouldbeabletoanalyzetheconstructionofanyother
core. InaUshapedaircellcore,aircellsareformedbyUshapedfins
which zigzag from the tip of thecoretothebottom,deflectingthe air.
Thewaterdropsalmostdirectlyfromtheuppertanktothelowertankin
70

thiscore.ThediamondshapedcellconstructionresemblestheUshapedcell
constructionexceptthattheribbonszigzaginthesamepatternasthefins,
thuscreatingdiamondshapedairpassages. Thewaterpassagesbetweenthe
ribbonsareirregularandthereforemoreefficientincooling,butaremore
easily clogged. Each fin has many bumps and ridges, called deflectors,
whichincreasethecoolingareaexposedtotheair. Somehoneycombcores
have square cells. The water has much farther to travel here than in a
diamond cell core, since the continuous water passages are alternately
verticalandhorizontalratherthandiagonal. Thehoneycombtypecorehas
severaldisadvantages. Althoughitexposesalargesurfacetotheair,it
is rather frail, and its irregular passages clog easily. Much of the
external surface of honeycomb radiators dispels heat indirectly and hence
loses effectiveness. Itisalsodifficulttomanufacturemetalribbonof
the thinness used in honeycomb radiators without producing holes,
excessivelythinpieces,orsteelburrsthatmayrustoutandcauseleaks.
Thehoneycombcoreisusedmainlyonpassengercarsandlightdutytrucks.
b.
RadiatorCleaning.
Radiator cleaning has three purposes: to restore perfect radiation, to

facilitate soldering, and to remove obstructions to water circulation.
Variouschemicalsaltsanddirtfoundinthewaterofdifferentlocalities,
togetherwithgreaseandoilthatfindtheirwayintothecoolingsystem,
collect inside the water passages of the radiator and insulate the water
from the metal or stop circulation. This overheats the engine. Rust,
disintegratedrubberhose,andaccumulateddepositsfromantifreezeorstop
leak preparations will have the same effect. The water passages may be
cleaned by pressure flushing, boiling, or rod cleaning. Dust, lint, and
bugsoftenadheretothefinsurfacesinsufficientquantitytorestrictthe
airflowthroughtheradiatoranddecreaseitsefficiency. Spraycleaning
isthennecessary.
(1) FlowTesting.
(a) Before a radiator is cleaned, it should be flow tested to
determine how badly it is clogged. The flow tester is used for this
purpose.Thistesterindicatestheexactamountofwaterthat
71

willflow,bygravity,througharadiatorperminute.Thereadingindicated
onthetesteristhencomparedwiththeflowrateofanewradiatororwith
the specifications furnished by the manufacturer. The difference between
theactualrateandthespecifiedrateindicatestheamounttheradiatoris
clogged.
(b) Touseaflowtester,theradiatorissetonthestandprovided,
thenahoseisconnectedtotheradiatorinlet.Afterthehoseisconnected
securely, the pump is turned on, and the water flow is adjusted until a
constantlevelismaintainedinthetank.
CAUTION
Be careful when adjusting the flow rate. If you
accidentally push the lever too far, the water will
shootoutthetopoftheradiatorontotherepairman.
Thecapacityofthistesteris90gallonsofwaterper
minute,andhasgivenmorethanonepersonanunwanted
shower.
(2) PressureFlushing. Pressureflushingforceswaterbyairpressure
(approximatelyfivepsi)throughthewaterpassagesofthecore.Itmaybe
accomplishedintwoways:directflushing,inwhichwaterisforcedthrough
from top to bottom, as it flows in normal service; and reverse flushing.
The same equipment is required for both methods: water pressure, air
pressure,andaflushinggun.
(a) To clean a radiator by direct pressure flushing, screw the
radiatorcaponthefillerneckandattachaleadawayhosetotheoutlet
connectionofthelowertank.Withtheflushinggunintheinletconnection
of the upper tank, fill the radiatorwithwater. Becausewateralone is
ofteninsufficienttobreakloosethegrease,sludge,rust,andscalewithin
theradiator,itmaybenecessarytoaddsomegoodradiatorcleaner. When
thedepositsareloosened,turnthewateroffandadmitcompressedairto
the radiatorinshortblasts,addingwaterbetweenblastsuntilthewater
drainsoutclearandatanormalrate.Theairmustbeappliedgradually,
sincetheradiatorwillstandonlyalimitedamountofpressure.
72

(b) Reverse flushing is similar, except that the lead away hose is
attachedtotheinletconnectionandtheflushingguntotheoutlet. Both
methods of pressure flushing are effective when the radiator is not too
badlyclogged.
(3) Boiling Out Radiators. Sedimentsofirmlypackedintheradiator
thatpressureflushingwillnotremoveitmustbeboiledoutwithasuitable
chemical solution. The vat is made so that the radiator may be lowered
beneath the surface on a level controlled rack. After the radiator has
boiled for a sufficient amount of time, it is removed from the vat and
placedinaspraybooth.Inthespraybooththeoutsideoftheradiatoris
washedwithairpressureandwatertoforceoutdirt,bugs,lint,andother
materiallodgedbetweenthefins,sothatfreecirculationofairaroundall
partsofeachtubeandfinisrestored.Also,theinterioroftheradiator
isbackflushedwithairpressureandwater.
(4) CleaningSolution. Tomakeagoodcleaningsolution,dissolveone
pound of ordinary baking soda inonegallonofwater. Ifacommercially
preparedchemicalcleanerforradiatorsisused,followthedirectiononthe
container.
(5) Rod Cleaning. If flushing or boiling is inadequate, scrape the
inside of the water passages with a bristle brush or cleaning rod. For
tubularradiators,thismaybemerelyaroundwirewithitsendroundedto
avoidpuncturingthetube.Forhoneycomborcellularradiators,useaflat
stripofmetalwithedgesandendsrounded,notquiteaswideasthewater
passage,pushingitbackandforththroughthewaterpassages.
c. Testing Radiator for Leaks. Before testing a radiator to locate
leakage,inspectitcarefullyforvisibleleaksandsolderthempromptly,so
that the test will be sensitive enough to reveal less obvious defects.
There are two standard methods of testing: one by introducing air (under
lightpressure)intotheradiator,immersingitinwater,andlocatingthe
leaksbytheappearanceofbubbles;andtheother,byfillingtheradiator
withwaterandlocatingtheleaksbythemoistureseepingthrough. Either
testissatisfactory,althoughtheairtestmethodispreferred. Markthe
leaksassoonasfoundtofacilitatelocatingthemduringrepairs.
73

(1) VisualInspection.Depositsoflineormagnesialeftontheoutside
surfacesbyevaporatingwaterindicateleaksinaradiator.Beforeremoving
abadradiatorfromavehicle,inspectitforthesedepositstodetermine
the amount of repair needed. Experience will teach how to determine the
trueconditionofaradiatorfromobservation. Thereareatleastasmany
leaksascanbeseen.Donotmakeanairorwatertestuntilalltheleaks
indicatedbyvisualinspectionhavebeenrepaired,becausetheeffectiveness
ofthesetestsindiscoveringhiddenleaksislostwhentheyrevealobvious
leaks.
(2) Airrest. Theairtest,socalledbecauseleaksareindicatedby
escapingair,isthemostefficientmeansoflocatinghiddenleaks.Connect
anairpressuretubedirectlyorbyanippletothebottomoftheoverflow
pipe. Screw the cap tightly on the filler neck and plug the inlet and
outletwithexpandingorcupshapedrubberstoppers. Immersetheradiator
inatestingtank,releasetheair,andtracethebubblestotheirsource.
(a) The most practical pressure for testing is three pounds per
squareinch(psi)abovenormaloperatingpressure. Greaterpressureswill
damagethedelicateconstructionofradiatorcores.Frequently,leakswill
appear at low pressure but not at high pressure, which closes the joints
withaccumulatedlimeandmagnesiadepositsorwithexpandedmetal.
(b) The air pressure system used by garages for tire inflation,
consisting of a compressor, motor, pressure tank, gages, and reducing
valves,isverysatisfactoryforradiatortestingwhentheworkisenoughto
keepseveralmenbusy. Whennocompressorisavailable,anordinarytire
pumpwillsupplyenoughairpressure.
(3) Testing Bench. Since testing is a dirty job, arrange the shop
equipmentsystematicallytominimizedisorder.Thetestingbenchshouldbe
placednearanairpressuresourceandwaterlines,preferablyendwisetoa
wall under or just back of a window, to light the radiator adequately.
Prevent damaging the radiator by excessive air pressure by using an air
pressuregage,andbeguidedbyit.
74

(4) FieldTestTask. Afieldtesttankconsistsofaonepiececanvas
bagwithwoodenstavesinpocketstoholdthesidesup,andfourroundpoles
runningthroughcanvasloopstosupporttherim.Arubbermatprotectsthe
bottom of the tank from being torn by the radiator. When the tank is
collapsed,twopolesareremovedandplacedinsidethetank,whichisthen
rolledinsidethematandfastenedwithfiveflatmetalhooks.
(5) Locating Leaks. Locating the leaks when bubbles rise is often
difficult. Raisetheradiatorinthetankuntilthesourceofthebubbles
is at the surfaceofthe water. Locateasmanylargeleaksaspossible,
drawing upon the knowledge of radiator construction; quite frequently the
largeonescanbedetectedmoreeasilyatalowerpressure. Repairthese
and retest for smaller ones. If water leaks in and remains for a later
test,itmaysealthecompressedairandpreventitfromescaping,andthus
causeleaksinthebottomtoremainundiscovered. Thenonthelasttest,
turntheradiatoroverinthetank.
(a) Two leaks occurring exactly opposite one another, one near the
frontofthecoreandtheotherattheback,shouldnotbeconfusing. If
testingahoneycombcore,standitonedge,allowingthebubblestocomeup
the face. A tubular core should be raised until only the lower rows of
tubesareimmersedinthewater.Anaccurateideaofthelocationofleaks
isbaseduponathoroughunderstandingofcoreconstruction.Tolocateopen
seamsatthebackofatube,useasharppointedtool.
(b) Tofindverysmallleaks,placethebenchlightinbackofthe
radiatorsothattheinteriorofthecorecanbeseen.Standtheradiator
onthebenchandspreadthesupposedleakwithfluxorsoapywaterfroman
eyedropper,oilcan,acidbrush,orswab.Compressedairseepingthroughthe
leakwillcausetheliquidtofoam.
(c) As heavy truck cores occasionally come to the shop with water
tanks removed, the water passages or tubes may have to be closed before
tests can be started. For a honeycomb core, solder dummy tanks to the
headerstrips.Thesemaybemadeofdiscardedtanksorplatemetal,toone
of
75

whichatubehasbeensolderedfortheairhose.Thetoolshowninfigure
36fortestingindividualtubes,issimplyacoreshapedrubberstopperwith
a1/4inchdiameterholeatthelargeend,increasingabruptlyto1/2inch
atthesmallend.Abrasstubeextendsthroughthe1/4inchopeningtothe
beginning of the 1/2 inch hole. A washer soldered onto the brass tube
preventsitfrombeingpushedinfurther.Theairhoseisslippedoverthe
tube. Tousethetesttool,submergethecoreinatesttank,placethe
tooloveroneendofthetubetobetested,andallowthewaterinthetube
tobeblownoutbytheairpressure.Then,withtheradiatorlevel,close
the opposite end of the tube with a finger. Bubbles will then appear
whereverthetubeleaks.
FIGURE36.TESTTOOLFORTUBULARCORES.
(6) WaterTest. Thewatertest,socalledbecauseleaksareindicated

byescapingwater,replacestheairtestwhenequipmentislimited,or
76

supplementsitwhentheairtestissuspectedofbeinginadequate.Sediment
andlimedepositedaboutleakyjointsmaybeforcedintothejointsbyair
pressurewhentheradiatorisairtested,sealingtheleak. Aleakatthe
joint of tubes and header plates often refuses to show up under air
pressure.Forthisreason,drytheradiatorafterrepairingtheleaksfound
byairpressure,andtestbythewatermethod.Withtheradiatorthoroughly
dry,removetheplugfromthefillerneckandfilltheradiatorwithwater,
beingcarefulnottorunitoverorspillontheoutside.Examinethecore
carefullyforleaks.Placetheairhoseoverthelowerendoftheoverflow
tubeandholdthepalmofthehandoverthefillerneck,whilefivepounds
ofpressureisappliedagainstthewater.
(7) MarkingLeaks. Adoptauniformsystemofmarkingleaks. Fortank
leaks,asharppointedtoolismostadaptable.Forhoneycombcores,benda
stripoftinorsmallwireintheshapeofaclothespinandinsertit,bent
end first, at the leak. Let oneendofthe"clothespin"projectfarther
thantheothertoindicatewhichsideofthecellisleaking.
d. RadiatorDisassembly.Whenworkisbeingperformedonvehicleradiators
using the oxyacetylene welding torch as a source of heat, the flame is
alwaysadjustedtoacarburizingflame.
(1) SideMemberRemoval.Lightandadjusttorchtoacarburizingflame.
Apply heat to the top radiator tankwherethesidemembersarejoined by
solder(onesideatatime). Whenthesoldermelts,movethetopofthe
sidememberawayfromtheuppertankuntilthemetalcools,thenheatthe
bottompartofthesidememberandremoveitfromtheradiator.
(2) Overflow Pipe. Melt any solder tacks which might be holding the
overflowpipetotheuppertank.Beattheoverflowpipeattheplacewhere
itentersthefillerneckandremoveitfromtheradiator.
(3) UpperTankRemoval.
(a) Tapping. Usingtheoxyacetyleneweldingtorch,directtheflame
to a point where the upper tank and header plate join. When the solder
startstomelt,tappingiscommenced,movingalltheway
77

aroundthetankuntilthecycleiscompleted.Thehandleofawirebrushis
idealforthisoperation. Asthetorchismovedthebrushhandlefollows,
keepingapproximatelythreeinchestotherearoftheflameatalltimes.
The vibration, set up by the constant tapping, prevents the solder from
resealing.
(b) Air Blowgun. To protect the eyes against molten solder and
fluxes, goggles or face shields must be worn when using this method.
Precautions must be taken that persons walking or working nearby are not
exposedtothefluxesorhotsolderthatmightbeflyingthroughtheair.
Applythetorchuntilthesolderstartstoflow;quicklyblowoutthemolten
solder withafullblastof air. Proceedaroundtheentiretankin this
manner,heatingtwoorthreeinchesofseamatatime.
(4) LowerTank. Thelowertankisremovedinthesamewayasthetop
tank.
(5) Filler Neck. Using apair of slipjoint pliers, holdthe filler
neckandapplyheattothesolderuntilmelted,andremovefromtheupper
tank. Itmustbedeterminedwhattypemetalhasbeenusedforthefiller
neck,inletpipe,andoutletpipe.Somelargestationarytypeengines,such
aslightplants,haveradiatorsthatmayhavecastironparts. Greatcare
must be takennottodestroy thetinnedsurfaceofthesemetals. If the
tinnedsurfacesaredestroyed,theymustberetinnedbeforeassembly.
(6) InletPipe.Holdtheinletpipewithapairofpliers,applyheat,
andremove.
(7) Baffle Plate. The baffleplate is solderedto the inside of the
upper tank. On some radiators, baffle plates are riveted and soldered.
Rivets should be removed prior to applying heat. Once the rivets are
removed,heatisappliedtothebaffleplateanditisremovedinthesame
mannerasonenotriveted.
(8) Outlet Pipe. The outlet pipe is removed in the same way as the
inletpipe.
78

(9) DrainCocks. Draincocksarefoundatthebottomofradiatorsand
areattachedtothelowertankinoneofthetwofollowingplaces:
(a) If the drain cock is attached to the outlet pipe, it may be
removedbyunscrewingit.
(b) Ifthedraincockisnotattachedtotheoutletpipe,it(ora
tapped fitting) is sweated to the bottom tank and is removed upon the
applicationofheat.
e. RadiatorAssembly.Agoodsolderingjobisdependentuponthecomplete
tinning of the metal prior to soldering. The use of a proper flux, the
close union of the parts to be soldered, and the application of adequate
heattomakethesolderflowfreelyareimportant.
Tinningcompoundiscomposedofpowderedtinandotherchemicalingredients
compoundedtogether.Whenmixedwithwater,itmakesanoilyliquid.This
liquid,whenappliedtoametalsurfaceandheated,willleaveadepositof
tinortincoating.Itisnotintendedforusewithaluminumormagnesium.
Thecompoundismixedwithahalfcanofwaterinitsowncontainer. The
fluxaidsthecompoundincleaningthemetal.Itisawhitepowderandis
mixedonaratioof1poundoffluxtofivepintsofwater. Thisfluxis
ideal for useon radiator workafterthepropertinningofthemetal has
been accomplished. It will cause the molten solder to have an excellent
capillaryaction.Whenusingflux,cautionmustbetakentokeepitoutof
anyopenscratchesorcutsintheskin.Rubberglovesshouldbewornwhen
workingwiththisflux.
Themostcommonlyusedfluxishydrochloric(muriatic)acidwhichhasbeen
cut(killed)byaddingpurezinc.Inpreparinghydrochloricacidforusein
soldering,placethedesiredquantityinacrockorotherearthenvesseland
addzincuntilitissaturated. Uncutmuriaticacidisayellowishcolor.
It becomes clear after it has been cut with zinc. Muriatic acid is
objectionablebecauseofitseffectsontheworkman,duetothegasesgiven
offwhenheated.Thereactionofhydrochloric(muriatic)acidwhenzincis
addedproducesasexplosivehydrogengas;therefore,thesolutionshouldbe
preparedoutdoors.
79

Themostcommonmaterialusedasasoftsolderbondisanalloycomposedof
50 percent tin and 50 percent lead. There are two types of solder
manufacturedfortherepairofvehicleradiators.Thesetypesareacidcore
andwiresolder.
Allsolderisremovedfromthepartspriortoassembly.Anyareathatshows
signsofnotbeingtinnedmustberetinned. Iftheoxyacetylenetorchis
used,theflameisadjustedtoacarburizingflame. Ifthesolderingiron
isused,thecopperpointmustbeproperlyheatedandtinned.Ifthecopper
pointistoocold,thesolderwillnotflowfreelyandwillnotsticktothe
metal.Ifthecopperpointistoohot,thesolderwillformlittleglobules
that will run off the surface of the metal. A small amount of solder
properlyflowingintothejointwillgiveamuchbetterresultthenajoint
that has solder piled up in a rough seam. A good soldering job is
recognizedbythemannerinwhichitflowsintothejoint.Arough,lumpy
seamindicatesapoorjob.Aseamorjointofthiskindshouldbegoneover
withaproperlyheatedirontoflowdowntheridgeandtopickuptheexcess
solder.Thespeedwithwhichsolderingcanbedonewithatorchflameisan
advantage.Itispreferredoverthesolderingironformostpurposes.The
methodofapplyingsolderwiththetorchissimilartothemethodusedwith
the soldering iron. With the torch, solder is melted and flows directly
uponthesurfaceofthemetal. Theheatofthemetalandthetorchflame
are bothessentialtoliquefythesolder. Satisfactoryrequirementsofa
torchflameare:
(1) Willnotbeextinguishedbythefumesofthefluxoracid.
(2) Givessufficientheattoaccomplishquickfusionofthesolder,and
yetnothotenoughtodamagethemetalbeingsoldered.
(3) Adjustedtosuitthejobtoincludealong,slim,needlelikeflame
capableofreachingdifficultplaces,aswellasaheavy,bushytypeflame
fordismantlingparts.
Variousgasescanbeusedforsolderingwithsatisfactoryresults.Hydrogen
gas, supported by compressed air, produces a flame that is very
satisfactory.Thisgasmaynotalwaysbeavailable.Acetylenegasisalso
used,butisnot
80

the most satisfactory. Because of the high degree of heat generated by
usingacetyleneandoxygen,thereisadangerofdamaginglightmetal.City
ornaturalgasisthebest;nextisliquidpetroleum;andlastoxyacetylene.
After themetalhasbeencleanedandretinned,reassemblyoftheradiator
canbegin.Thereisnoprescribedpatternofreassemblyexcepttheradiator
baffleplatemustbeinstalledfirst. Allpartsarefluxedwithsuitable
fluxandsolderedtogether.Theuppertankissetinplaceonthecoreand
tack soldered on each corner. After tacking in place, solder each end.
Aftertheendsaresoldered,startononecornerofthetankandsolderthe
tankallthewayaround.
f. RepairingRadiatorLeaks.Afterleakshavebeenmarked,theradiatoris
removedfromthetesttankandrepaired.
(1) SeamLeaks.
(a) Applyheatandremovetheoldsolder,usingtheairgunorwire
brushmethod.
(b) Oldsolderisremovedforadistanceofthreeinchesoneachside
oftheleak.
(c) Using a squirt bulb or an acid brush, flush the seam with
muriaticacid.
(d) Beat the seam until the acid boils, then quickly blow or wire
brushouttheacid. Thisremovesalldirtandoxides,whicharethecause
ofpoorsolderbonding. Caremustbetakennottodirecttheairstreamor
wirebrushtowardanyonewhenremovingacidorhotsolder.
(e) Flush seam liberally with flux, using a squirt bulb or acid
brush. Keep seam warm with torch while flushing. Remove all flux with
moderateairstream.
(f) Proceedwithsolderingintheusualmanner.
(2) PatchingCrackedTanksBrassRadiatorTanks. Almostallradiator
tanks are castor stamped in onepiecetoreducethenumberofpotential
leaks.
81

(a) Cracks in stamped brass radiator tanks must be patched.
Spreadingsolderoverthecrackwillnotmakeapermanentwatertightrepair.
(b) Wire brushorscrapetheareaaroundthecrackoneinchlarger
than the patch to be installed. Dig down into the crack itself with a
pointedtool.Tinthecleanedareasandtheundersideofthepatch,wiping
themcleanwhilethesolderisinamoltenstate.
(c) Fit the patch in place as perfectly as possible, following the
contoursofthetank.Allpatchesshouldhaveroundedcorners.
(d) Holdthepatchinplacewithascrewdriverandapplyheat. The
proper amount of heat will be indicatedwhenastickofsolderwill melt
whentouchedtothepatch.
(e) Ifpropercarehasbeentakenduringthetinningoperation,the
patch will be strong and watertight. Hold the patch in place until the
solderhasset.
(3) BlockingofTubesCellular(honeycomb)Radiators. Adamagedtube
maynotneedtoberepaired;itcanbeblockedoff.Fifteenpercentofthe
tubesinaradiatormaybeblockedoffwithoutadverseeffects.
(a) Heat face of tube near header plate and spread open with an
improvisedtoolmadefromanoldhacksawbladesharpenedononeendtothe
shapeofachisel.
(b) Thoroughly tin the inside of the tube with tinning compound,
usinganacidbrushtoapplythetinningcompound.
(c) Applyfluxandfilltubewithsolder.
(4) TubularCore.
(a) Heatfinsattheheaderplateandraisefinsonehalfofaninch
oneachsideofthetubetobeblocked.
(b) Applyheattothetubeandblowoutthesolderwithanairgun.
82

(c) Reheatthetubeattheheaderplate,andusingapairofneedle
nose pliers, bend the tube down and out to one side and remove from the
headerplate.
(d) Retintheareawherethetubewasremovedfromtheheaderplate.
(e) Applyfluxandsoldertheholeshut.
(f) Repeatthesameoperationattheotherheaderplate.
g. Straightening a Bent Radiator Core. A bent radiator core can be
straightened,providedthebendisgradual.Ifitissosharplykinkedthat
the watertubesorpassagesarecollapsed,itshouldnotbestraightened.
Straighteningisdoneinapress,withboardsaboveandbelowthecore,to
spreadthepressureandprotecttheairfins.Hydraulicpressesmaybeused
forthisoperation.
WARNING
Epoxy materials maycauseskinirritation. Ifepoxy
resinsandhardenerscomeintocontactwiththeskin,
wash the skin thoroughly with mild soap and water.
Always use epoxy resins and hardeners in a well
ventilatedarea.
h. RepairofAluminumRadiators.Damagedradiatorsarerepairedwithepoxy
resins,glasscloth,andaluminumscreen. Duetothelimitedstoragelife
oftheresinandhardener,repairofaluminumradiatorswithmaterialwhich
has been in storage for more than one year is not recommended. Mixing
ratiosofepoxyresinstohardenersnormallyaregivenbyweight.Theratio
byweightis100partsepoxyto1417partshardener.
Whenweighingequipmentisnotavailable,56partsepoxyresinbyvolumeto
1parthardenerbyvolumeistherecommendedvolumemixingratio.The5to
1ratiowillproduceacompoundwithashorterpotlife(workingtime)than
the 6 to 1 ratio (working life of the resin hardener mixture is
approximately 15 to 25 minutes at75degreesF). Ifdesired,the entire
contents of both the hardener and resin cans may be used by adding the
contentsofthehardener
83

cantothatoftheresin,whichwillresultinthecorrectmixingratio.
i. RepairProceduresforEndTanks. Forholesorlacerationsintheend
tanksoftheradiator,trimawayraggededgesandcleanwithawirewheel.
Blow away dust and clean the repaired area with naphtha or paint thinner
followedbyalcohol.
NOTE
Thepresenceofoilintherepairareawillresultin
poor adhesion. Repair of holes larger than
approximately1inchindiameterisnotrecommended.
(1) Cuttwopiecesofaluminumscreeningslightlylargerthanthehole
andthenwiretogethersothattheradiatormaterialissandwichedbetween
thescreening.
(2) Prepareaproperamountofepoxyresinandhardenerasdirectedin
subparagraph i above. Add a sufficient amount of silica to obtain a
workableconsistency(soft,puttylike).
(3) Thoroughlysaturatethescreeningwiththeepoxymixture.
(4) Cutapieceofglassclothlargerthanthehole,saturatewiththe
epoxymixture,andformitovertheholeandcleanedsurroundingarea.For
holeslargerthan1/2inchindiameter,asecondclothlayerisrecommended.
Place a piece of release film on the second patch and with a hardwood
depressor,workoutthetrappedairpocketsbyworkingfromthecenterof
thepatchoutward.
(5) Applyanothercastofepoxymixtureovertheglasscloth.
NOTE
Curewillbeslowintemperaturesbelow70degreesF.
Curemaybeshortenedtoaboutfourhoursbyplacinga
heatlampoverthepatchareaandgraduallyincreasing
the heat intensity by moving the lamp closer to the
repairedarea.
84

CAUTION
Repairareatemperaturemustnotexceed100degreesF
anytimethereafter.Minimumdistancebetweentheheat
lamp and repair area is two feet, regardless of the
temperaturerequirement.
(6) Allowthecompletedpatchtosetundisturbedfor16to24hours.
j.
RepairProceduresforCores.
(1) Forlacerationsinthecore,removefinsapproximately1/2to3/4of
aninchbeyondthedamagedcrosstubes.
(2) Removejaggededgesfromthecrosstubes,cleanwithapenciltype
wireorgrindingwheel,andcontinuepreparation.
(3) Prepareaproperamountofepoxyandhardener.Alsoaddsufficient
amountofsilicatoobtainaworkableconsistency(soft,puttylike).
(4) Forcetheepoxymixtureintothecrosstubeandclosethetubewith
pliers. Applyasecondcoatofepoxymixtureovertheclosedofftubeand
immediatesurroundingarea.Allowtherepairtodry.
CAUTION
Donottestaluminumradiatorsinatankthathasbeen
or is being used for testing copper/brass radiators.
Fluxes used in copper/brass radiator repair will
contaminatethewaterinatesttankandwillattack
aluminum.
(5) Test. To test the radiator repair, block all inlet and outlet
connections,installpressurizingequipment,andapply18psiforaperiod
ofthreeminuteswhiletheradiatorisimmersedinwater. Absenceofair
bubblesdenotesasatisfactoryrepair.
85

(6) CleaningandPainting.
CAUTION
Radiators should never be painted with ordinary
lacquers,enamelsorpaintsastheseinsulatetheheat
transfer. This reduces the cooling efficiency.
Alwaysusenoninsulatingradiatorcorepaint.
Afterallleakshavebeenrepaired,theradiatorshouldbepainted.Anon
insulating paintshouldbeused. Beforepainting,theradiatorshouldbe
cleaned,dryandfreeofallfluxresidue.
NOTE
No more than one coat of paint will be applied to
radiatorcoresontacticalwheeledvehicleswhichare
subjecttopainting.
2.
Conclusion
This task introduced the specific operation required to repair radiators.

Thenexttaskwillpresenttheprocedurestobefollowedforrepairingfuel
tanks.
86

LESSON2
TASK3. Describetheoperationsrequiredforproperfueltankrepair.
CONDITIONS
assistance.
STANDARDS
Withinonehour
REFERENCES
1.
Introduction
Fuel tanksformotorvehiclesaremadeofterneplateranginginthickness
from No. 24 (0.0156 inch) to No 18 (0.050 inch) U.S. standard gage, and
joinedbyweldedseams.Fittingssuchasthefillerneck,drainvalve,and
fuellineconnectionsaresolderedtothetank. Baffleplatesinsidethe
tankoffsetexcessivesplashingandfoamingofthefuelwhenthevehicleis
in motion. Figure 37 (on the following page) illustrates typical
constructionforafueltank.Leaksmayoccurintheseamweldsorsoldered
joints because of vibration, strain, or faulty construction. Occasional
leaksinthetankitselfarecausedbysharpobjectssuchasstonesorbolts
picked up bythewheelsof thevehiclefromtheroadwhichcanbe thrown
againstthefueltank.
2.
TypesandConstruction
Fuel tanks are made in various shapes and sizes, from the smallest for
outboardmotorstothelargestrailtankcars.Themostcommontypeof
87

FIGURE37.TYPICALFUELTANKCONSTRUCTION.
fuel tank used in the Army are wheeled vehicle tanks (terneplate),
fiberglass fuel tanks, cell or bladdertype tanks, and fuel compartments,
which are part of tracked vehicles. Terneplate is thin gage, lowcarbon
steelwhichiscoatedonbothsideswithlead.Duringitsmanufacture,the
steelisrunthroughanacidbathandthenthroughahotleaddip.Thelead
coating adheres to the metal, givingitatinnedcoat. Thistinned coat
preventsrustfromformingontheinsideofthetank,andalsomakesrepairs
easier.
Regardless of their shape and size, all fuel tanks must be designed to
preventstaticelectricityandexcessivesplashing.Baffleplatesareused
forthispurpose.Figure38(onthefollowingpage)showstheinsideofa
fueltankusedona21/2tonArmyvehicle. Baffleplatesaresecuredto
thetop,bottom,andsidesofthetankbyspotweldingorsoftsoldering.
NewertypevehiclesbeingissuedtotheArmyhavefueltankbaffleplates
spotweldedtopreventthenfrombreakingloose.
88

FIGURE38.CUTAWAYVIEWOFFUELTANK.
3.
RepairOperations
a. FuelTankBodyandEnds.Thetankbodyandendsaresecuredtogetherin
oneofthreeways:
(1) Crimpedandsoldered.
(2) Tankendsflangedandseamweldedtothetankbody.
(3) Aluminumfueltanksbrazedorfusionwelded.
Commercial type vehicles have upper and lower tank halves seam welded
togetherinthecentertomakeacompleteunit.
Fueltankson3/4tonandlargercombattypevehiclesareflangedandseam
welded.
Fueltankson1/4ton(Jeep)combattypevehiclesareeitherseamweldedor
soldered.
After one endhas been installedonthetankbody,thebaffleplates are
spotweldedinplace.The
39

remainingtankendissecuredinpositionbyseamwelding.
b.
FuelTankFittings.
(1) FillerNeck.Fillernecksonfueltanksaremanufacturedfromcast
iron, aluminum, or low carbon steel, then coated with lead, stamped to
shape,andsolderedinplace.
(2) FillerTube(sleeve)Assembly.Thefillertubeisaroundcylinder
manufacturedfromterneplate.Itisusedasanextensionofthefillerneck
topreventfuelfromsloshingoutofthetankwhilebeingfilled. Located
inthebottomofthesleeveisascreen(brasswiremesh)topreventdirtor
otherforeignparticlesfromgoingintothetank.Whenfuelistobeadded
tothetank,thesleeveispulledupandlockedinposition.
CAUTION
When repairing a fuel tank, make certain that the
sleeve lock is in proper working condition. If it
does not make good contact with the tank, static
electricity may result when filling and an explosion
couldresult.
(3) Filler Cap. All fuel tank filler caps are not alike. Some are
plainlockontypeswhileothersaredesignednotonlytopreventthegas
from sloshing out, but to allow combattype vehicles to be used in deep
waterfordingoperations. Figure39(onthefollowingpage)illustratesa
crosssectionviewofapressuretypefueltankfillercap. Operationof
thepressurecapisdescribebelow.
(a) Asroadheatcomesincontactwiththefueltank,thefuelwill
starttoexpand,causingtheairwithinthetanktobecompressed.Atthis
time, pressure put on the compression spring opens the vent and lets the
expandingfuelvaporsescapefromthetank.
90

FIGURE39.PRESSURETYPEFUELTANKFILLERCAP.
(b) Thereverseofthis(paragraph3b(3)(a))occurswhenthetankand
fuelcool.Airmustbebroughtinfromtheoutsidetoreplacethearealeft
by the shrinking fuel. Atmospheric pressure, which is greater than the
pressurewithinthetank,forcestheinletventopen,allowingairtorush
intothetank.Whenthetankpressureequalsatmosphericpressure,theair
ventcloses.
(4) FuelPickupConnectionPlate. Theconnectionplateismanufactured
fromlowcarbonsteel,coatedwithlead,andsolderedtothetankbody.The
platehasholesdrilledintoitandtappedtoreceivethefuellinepickup
assemblywhichissecuredinplacewithscrews.
(5) FuelGageConnectionPlate. Constructionandmethodofattachment
isthesameasthepickupplate.
(6) DrainPlug.Thedrainplugisasteelplugwithpipethreads.The
drainplugfittingismanufacturedfromlowcarbonsteelcoatedwith
91

lead,withinternalpipethreads,andsolderedtothetankbody.
c. FiberglassFuelTanks. Fiberglassfueltanksareconstructedentirely
of fiberglass, except for the fittings or connections. Because of their
light weight, durability, and seamless construction, they are used
frequently on armored personnel carriers and selfpropelled artillery
vehicles.
(1) Their construction makes it possible to install them in irregular
spaces.Theyareusedmainlyinvehiclesthataresubjecttovibrationand
traveloverroughterrain. Becauseoftheirirregularshapes,theydonot
needbaffleplates.
(2) Cell or bladdertype tanks are constructed of three layers of
syntheticmaterialandaprotectivelacquercoating.Theyaresimilartoa
largeballoonandaresquareorroundinshape.Theyaresometimesusedas
temporaryorportablefuelcellsandmostunitsinthefieldusethemfor
fuelpoints.Theirthickwallconstructionprovidesanexcellentshieldfor
foulweatherorabuse.Whennotinuse,theyeasilyfoldawayforstorage.
(3) The fuel compartment is not an independent section or a tank and
cannotberemovedfromthevehicle. Itisconstructedasanintegralpart
ofthevehicle'shull.Thecompositionandshapeofthefullcompartmentis
determinedbythedesignoftheparentvehicle.
d.
TestingforLeaks.Threemethodsareusedtolocatefueltankleaks:
(1) Visibleleaksarefoundbylookingforstainsleftontheoutsideof
thetank.Seepagemarkswillbedarkbrownordarkred(dependingonwhat
typeofgasisused)stainsonthetank.Cracksmaybelocatedbycareful
observationofthetank.
(2) Thebesttestistheunderwaterairtest.Thetankmustbecleaned
prior to testing. It is then made airtight by sealing the fluid gage
opening, the fuel filler pipe opening, and the drain plug, and then
attachinganairhoseconnectedtothefueloutletconnection. Placethe
tankinavatoracanvastank.Applycompressed
92

airofnomorethanfivepsi,andlookforairbubbles. Markthesespots
andrepair.
(3) Another method is to fill the tank with clean water, soap the
outside ofthetank,replacethetankcap,andattachanairlineto the
fuel outlet connection. Apply fivepsiofairpressureandlookfor any
bubbleswhichmayappearontheoutsideofthetankwhichindicatesaleak.
(4) Testingforleaksinthefiberglassandcell(bladder)typeoffuel
tankismoreorlessamatterofvisualinspection.Incell(bladder)type
fueltanks,leaksmayoccurbecauseofpunctures,cuts,abrasions,blisters,
andruptures.Scuffsandcoatingdamagemayalsocauseoccasionalleaks.
e. Cleaning.Beforerepairs,fueltanksmustbecleanedthoroughly.This
is absolutely necessary as a safety precautionagainst fuel or vapors
remaininginthetank.Neverbemisledbythefactthatthetankisempty
ofliquid.Theremaybevaporsinatankthathasbeenemptyseveralweeks
ormonths.Whenheatisappliedtothetank,themetalexpandsandanyfuel
thatmayhavebeentrappedintheseamsvaporizesandexplodes.
(1) Thebestmethodofcleaningafueltankisthelivesteammethod.
Thisconsistsofusingasteamcleanertoremoveanyfuelorfumesthatmay
stillbepresent.Afterflushingthetankwithwater,removealltankunits
and fittings such as the drain plug, fuel pickup assembly, gas gage, and
fillercap.Placethesteamcleanerhoseinthefillerneckandsteamthe
insideofthetankforatleast45minuteswithlivesteam.Repairsshould
bedoneimmediatelyaftercleaning.
(2) The exhaustandair method does not require anything more than a
vehiclethatrunsanda11/2inchflexiblepipe.Removethetankfromthe
vehicle.Placethe11/2inchflexiblehoseintothegastankfillerneck.
Connecttheotherendtoanothervehicleexhaustpipe.Letthevehiclerun
foratleast25minutes.Aftertheexhaustfumeshavebeenrunningintothe
fueltankforatleast25minutes,blowthetankoutwithcompressedairand
startrepairsimmediately.Bystartingrepairsimmediately,vaporshavenot
hadachancetobuildupagain.
93

(3) Thelivesteamandtheexhaustandairmethodsareusedmainlyfor
terneplate tanks, but they can also be used on fuel compartments. The
waterfilledmethodisanothermeansofcleaningfueltanks.Afterlocating
aleak,fillthetankcompletelywithclearwaterandreplacethefuelcap.
Thenturnthetankuntiltheleakisinthetopmostpositionandrepairwith
asolderingirononly. Forfiberglassandcelltypetanks,aplainwater
flushisthebestmethodofcleaning.
(4) Patching.Beforepatchingadamagedtank,firstremoveitfromthe
vehicleandremoveallvapors.Theareatobepatchedmustbecleanedand
tinnedatleasttwoinchesbeyondthecrackinalldirections.Whencutting
a patch, use galvanized metal large enough to extend beyond the crack at
least1inchinalldirections.Roundallcornersandtinthemetalonthe
sidethatistomakecontactwiththetank.Placethepatchonthetankand
sweatsoldertogether.Thelaststepistotestwithfivepsiairpressure.
(5) SafetyRules.Safetyrulesforfueltankrepairshouldbestrictly
enforced.
(a) Donotdependonyoureyesornosetodecideifitissafetoput
an open flame on a fuel tank; steam it first. A very small amount of
residualgasolineorotherexplosiveliquidcancauseaseriousexplosion.
(b) Neveruseoxygentoventilateafueltank.
(c) Neverplacealightedtorchorflameofanykindinthefueltank
openingtotestforvaporsafterithasbeencleaned.
(d) Alwaysusecompressedairtocleantheexhaustfumesfromafuel
tankwhentheexhaustmethodhasbeenusedtoremovefuelvapors.
(e) Never use an oxyacetylene torch to remove tops of 55 gallon
drums.Alwaysuseahammerandcoldchisel.Alltypesof55gallondrums
should be cleaned before removing the tops. Vapors of some liquids will
explodeuponthefirstspark.Sincecoldchiselsaremadeofsteel,aspark
could very easily be struck. With priority on safety, only drums which
containknownnontoxicsubstancesshouldbeused.
94

Before the actual repair of a tank, the vapors must be removed and the
fillerneckcapreplaced.Afterconnectingtheairhosetothefueloutlet
pipeconnectionandplacingthetankinawatervat,observethetankfor
anyleaks(withairpressuresetatfivepsi).Removethetankandshutoff
theairsupply.Torepairthedamagedarea,firstheatthearea,cleanor
wirebrushandtinthearea,andthensoldertheleak.Thefinalstepisto
retestwithairtomakesurethedamagedareawasrepairedproperly.
95

PRACTICALEXERCISE2
1.
Instructions
On a plain sheet of paper, write down the answers to the following

questions. When you have answered them, turn the page and check your
answers.
2.
FirstRequirement
a.
Whatarethetwomostcommonclassificationsforglass?
b. Temperedglasscanwithstandheavyimpactsandgreatpressures. Itis
madebyreheatingplateorwindowglassuntilitissomewhatsoftfollowed
bycoolingitinwhatmanner?
c. Whatistheinnermaterialthatisplacedbetweentwosheetsofglass
forminglaminatedsafetyglass?
d. What are the three operations that the process of cutting glass is
dividedinto?
e. Whyisitimportanttokeepaconstanttemperatureinaglasscutting
room?
f. Whatistheliquidthatshouldfirstbewipedaroundthecuttinglineof
glasstobecut?
g.
Whatkindofgrainisusedtogrindglass?
h. In addition to the use of protective covers and the inspection of

hardware, what is the most important general precaution to follow when
installingglass?
3.
SecondRequirement
a. Automobileandtruckradiatorsconsistoftwowatertanksjoinedbywhat
componentwhichdoestheactualcooling?
b. Radiatorfittingsarefoundonboththeupperandlowerwatertanksof
theradiator. Whentheyaremanufacturedasseparateparts,whatarethe
fourwaystheycanbeattachtotheradiator?
96

c.
Whatarethetwomostcommontypesofradiatorcores?
d. Radiatorcleaninghasthreepurposes:torestoreperfectradiation,to
facilitatesoldering,andtoremoveobstructionstowatercirculation.What
arethethreemethodsbywhichwaterpassagesmaybecleaned?
e.
Howmuchpressureisrequiredwhenpressureflushingaradiator?
f. Onemethodoftestingaradiatorforleaksistointroduceair(under
lightpressure)intotheradiatorandimmerseitinwaterandlookforair
bubbles.Whatisanothermethodfortestingradiatorsforleaks?
g. Whendisassemblingaradiator,anoxyacetyleneweldingtorchisusedas
asourceofheat.Thetorchisadjustedtowhattypeofflame?
h. Theuseofaproperflux,thecloseunionofthepartstobesoldered,
and the application of adequate heat to make the solder flow freely are
importanttoaccomplishingaproperradiatorsolderingjob.Whatisagood
solderingjobdependentupon?
i.
Whatisthecompositionofsoftsolder?
j. Themostcommonlyusedfluxishydrochloricacidwhichhasbeencutby
addingwhatcompoundtoit?
4.
ThirdRequirement
a.
Whatisthepurposeofhavingbafflesinsideafueltank?
b. The process of tinning the inside of a fuel tank prevents what from
forminginsidethetank.
c. Of the three possible methods for locating fuel tank leaks, what is
consideredthebesttestforthispurpose?
d. Beforefueltankrepairscanbeperformed,fueltanksmustbecleaned
thoroughly.Thebestmethodfordoingthisiscleaningthetankwithlive
97

steam. With the steam cleaner hose in the filler neck, how long should
steambeforcedintothetank?
e.
98
Canfueltanksberepairedbypatchingthetank?

LESSON2.PRACTICALEXERCISEANSWERS
1.
FirstRequirement
a.
(1)
(2)
b.
Temperedglassiscooledbyplacingitinahotoilbathorplacingit
quicklyagainstacoldmetallicsurface
c.
Toughplasticmaterial
d.
(1)
(2)
(3)
e.
Suddentemperaturechangeswillalmostcertainlyresultinbreakageof
glass
f.
Kerosene
g.
Siliconcarbideabrasivegrain
h.
Checkparts
2.
SecondRequirement
a.
Core
b.
(1)
(2)
(3)
(4)
Brazed
Soldered
Bolted
Riveted
c.
(1)
(2)
Tubular
Honeycomb
d.
(1)
(2)
(3)
Pressureflushing
Boiling
Rodcleaning
e.
Fivepsi
f.
Filling the radiator with water and locating the leaks by moisture
seepingthrough
g.
Carburizingflame
Leadglass
Lineglass
Makingthecut
Crackingthecut
Cuttingormeltingtheplastic
99

h.
Completetinningofthemetalpriortosoldering
i.
50percenttinand50percentlead
j.
Zinc
3.
ThirdRequirement
a.
Tooffsetexcessivesplashingandfoamingofthefuelwhenthevehicle
isinmotion
b.
Rust
c.
Underwaterairtest
d.
45minutes
e.
Yes
100
METAL BODY REPAIR - OD1653 - REFERENCES
REFERENCES
101
METAL BODY REPAIR - OD1653 - REFERENCES

REFERENCES
Thefollowingdocumentswereusedasresourcematerialsindevelopingthis
subcourse:
DAPam3101
FM924
FM432
TB9230024740
TM9237
102

Metal Body Repair PDF

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Metal Body Repair PDF

Uploaded by

Copyright:

Available Formats

SUBCOURSE

METAL BODY REPAIR

METAL BODY REPAIR - 0D1653

METAL BODY REPAIR - OD1653

METAL BODY REPAIR - OD1653

METAL BODY REPAIR - OD1653 - LESSON 1/TASK 1

In order to replace or repair damaged sections of an auto body, the

METAL BODY REPAIR - OD1653 - LESSON 1/TASK 1

METAL BODY REPAIR - OD1653 - LESSON 1/TASK 1

METAL BODY REPAIR - OD1653 - LESSON 1/TASK 1

(5) RearQuarterPanel. Therearquarterpanelisanintegralpartof

METAL BODY REPAIR - OD1653 - LESSON 1/TASK 1

(1) An understanding of the construction of the frame is extremely

METAL BODY REPAIR - OD1653 - LESSON 1/TASK 1

METAL BODY REPAIR - OD1653 - LESSON 1/TASK 1

METAL BODY REPAIR - OD1653 - LESSON 1/TASK 1

METAL BODY REPAIR - OD1653 - LESSON 1/TASK 1

METAL BODY REPAIR - OD1653 - LESSON 1/TASK 1

METAL BODY REPAIR - OD1653 - LESSON 1/TASK 1

(1) Dinginghammer(A) (figure6). Itisageneralpurposehammerfor

METAL BODY REPAIR - OD1653 - LESSON 1/TASK 1

METAL BODY REPAIR - OD1653 - LESSON 1/TASK 1

METAL BODY REPAIR - OD1653 - LESSON 1/TASK 1

(2) DoubleEndandLowerBeckQuarterPanelSpoon(B). Itisusedfor

METAL BODY REPAIR - OD1653 - LESSON 1/TASK 1

(1) AdjustableFileBolder. Thistoolquicklyadjustsfromanextreme

METAL BODY REPAIR - OD1653 - LESSON 1/TASK 1

METAL BODY REPAIR - OD1653 - LESSON 1/TASK 1

METAL BODY REPAIR - OD1653 - LESSON 1/TASK 1

METAL BODY REPAIR - OD1653 - LESSON l/TASK 1

METAL BODY REPAIR - ODl653 - LESSON 1/TASK 1

METAL BODY REPAIR - OD1653 - LESSON 1/TASK 1

(1) A metal picture frame is represented by (A) (figure 11) with

METAL BODY REPAIR - OD1653 - LESSON l/TASK 1

METAL BODY REPAIR - OD1653 - LESSON 1/TASK 1

METAL BODY REPAIR - OD1653 - LESSON 1/TASK 1

METAL BODY REPAIR - OD1653 - LESSON 1/TASK 1

METAL BODY REPAIR - OD1653 - LESSON 1/TASK 1

METAL BODY REPAIR - OD1653 - LESSON 1/TASK 1

METAL BODY REPAIR - OD1653 - LESSON 1/TASK 1

METAL BODY REPAIR - OD1653 - LESSON 1/TASK I

METAL BODY REPAIR - OD1653 - LESSON 1/TASK 1

METAL BODY REPAIR - D1653 - LESSON 1/TASK 1

METAL BODY REPAIR - OD1653 - LESSON 1/TASK 1

METAL BODY REPAIR - OD1653 - LESSON 1/TASK 1

(21) Thelasttesttobemadeinacoachstylebodyisacheck ofthe

METAL BODY REPAIR - OD1653 - LESSON 1/TASK 1

Before using the jack, size upthejobtodeterminethedirection of the

METAL BODY REPAIR - OD1653 - LESSON 1/TASK 1

METAL BODY REPAIR - OD1653

that has beenapplied in asemifluidstate. Thismaterialmayhave been

METAL BODY REPAIR - OD1653 - LESSON 1/TASK 1

METAL BODY REPAIR - OD1653 - LESSON 1/TASK 1

METAL BODY REPAIR - OD1653 - LESSON 1/TASK 1

(c) In thismethodofhammering,nohammermarksareformed onthe

METAL BODY REPAIR - OD1653 - LESSON 1/TASK 1

METAL BODY REPAIR - OD1653 - LESSON 1/TASK 1

METAL BODY REPAIR - OD1653 - LESSON 1/TASK 1

METAL BODY REPAIR - OD1653 - LESSON 1/TASK 1

METAL BODY REPAIR - OD1653 - LESSON 1/TASK 1

METAL BODY REPAIR - OD1653 - LESSON 1/TASK 1

METAL BODY REPAIR - OD1653 - LESSON 1/TASK 1

Knowledge ofthe metal body repairproceduresdescribedinthissubcourse