BODY REPAIR SHOP & CAR BODY

SHELL
AN OVERVIEW
Presented
BY

NAISHADH DESAI
SURVEYOR & LOSS ADJUSTER,
SURAT

JULY 26, 2009

At
M/S WELTECH MOTORS
SURAT

SALIENT FEATURES

AUTOMOBILE WORK SHOP

ACCIDENTS
VEHICLE
VEHICLE BODY SHELL
BODY SHELL REPAIR SHOP.
ACTIVITIES IN BODY REPAIR SHOP.
EQUIPMENTS OF BODY REPAIR SHOP
DEMO SEQUENCE OF DENT BEATING
PROCESS

AUTOMOBILE WORK SHOP

AN
AUTOMOBILE
WORKSHOP IS A ROOM
/ BUILDING / PREMISES
WHICH
PROVIDES
BOTH AREA / SPACE &
TOOLS / EQUIPMENTS,
THAT
MAY
BE
REQUIRED FOR REPAIR
/
MAINTANENCE
ACTIVITY
OF
ANY
AUTOMOBILE

MAJOR DIVISION OF AUTOMOBILE

WORKSHOP

GENERAL MAINTENANCE REPAIR SHOP

VEHICLE WASHING, TUNING, PREVENTATIVE,
ROUTINE AND MAJOR MAINATANANCE / REPAIR
WORK FOR ENGINE, TRANSMISSION, BRAKE,
ELECTRICAL, AIRCONDITIONING SYSTEM ETC OF
AUTOMOBILE

BODY SHOP
BODY SHELL REPAIR SHOP

DISMENTLING
GETTING RID OF RUST
CUTTING & WELDING
PANEL BEATING
DENT/REFABRICATION
REASSEMBLING
ALTERATION /
MODIFICATION

BODY SHELL PAINT SHOP

COMPLETE PAINT
RELATED ACTIVITIES

ACCIDENT

SKILL REQUIRED
BODY SHOP INCHARGE

ASSESSOR / CLAIM EXAMINAR

Knowledge of Vehicle
& its body
Better understanding
of job on hand
Job analysis skill
Process skill
Technology skill
Equipment skill

Knowledge of Vehicle
& its body
Better understanding
of job on hand
Job analysis skill
Process skill
Technology skill
Equipment skill

VEHICLE

BARE BODY SHELL

TYPE OF BODY SKILL
CONSTRUCTION OF BODY SHELL
MATERIAL OF BODY SHELL
SAFETY FEATURE S AND ITS
IMPORTANCE
ATTACHMENT OF BODY SHELL

VEHICLE
VEHCILE BE
DIVIDED IN TO
TWO MAJOR
COMPARTMENT
S
BODY SHELL
PERFORMANCE
SYSTEM

BODY SHELL
BODY SHELL OF
AN
AUTOMOTIVE
VEHICLE IS THE
STRUCTURE
WHICH
PROTECTS :
THE OCCUPENTS
ANY OTHER PAY LOAD
THE PERFORMANCE
PARTS
OTHER COMPONENTS

LADDER
FRAME
So named for its
resemblance to a
ladder, the ladder
frame
is
the
simplest and oldest
of all designs. It
consists merely of
two
symmetrical
rails, or beams,
and cross members
connecting them.
Originally seen on
almost all vehicles

UNI BODY
MONOCOQ
Monocoque or uni
UE
body construction,
in
which
the
"chassis" is part of,
and integrated with
the metal body. It
provides support to
all the mechanical
components, as well
as protection for the
vehicle occupants.
Although there is no
separate complete
frame or chassis

SUB FRAME
The sub frame, or stub frame, is a
boxed frame section that attaches to
a unibody. Seen primarily on the front
end of cars, it's also sometimes used
in the rear. Both the front and rear are
used to attach the suspension to the
vehicle and either may contain the
engine and transmission

MATERIAL
STEEL

ALLUMINIUM

POLY URETHENE, PLASTIC,

F.R.P.MATERIAL

COMPOSITE CARBON

PLASTIC / RUBBER

NOICE VIBRATION HARNESS

BODY SEALENT

DIAGRAM BODY FILLER

SAFETY FEATURES IN BODY SHELL

CRUMPLED ZONE
REINSFORCEMENT PANELS
REINFORCEMENT BARS
SAFETY BARS

BODY SHELL WITH ALL SAFETY

FEATURES

COMPLETE BODY SHELL

INCLUSIONS OF PANELS LIKE
FRONT BONNET, FENDERS, DOORS DICKY LIDS

REPAIRING CATAGORY
REPAIRING SIMPLE PANEL AREA
REPAIRING PANEL SUPPORTED WITH
FRAME
REPAIRING SANDWICH PANELS
REPAIRING PANELS SUPPORTED WITH
CRUMPLED ZONE AND REINFORCEMENT
PANELS
REPLACEMENT OF SIMPLE PANEL AND
WELDED PANELS

REPAIRING PROCESS &

EQUIMMENTS

PANEL
BEATING
BODY
BASIC
REPAIRING TECHNIQUE
MOST
REQUIRES
SKILLS
EXPERT KNOWLEDGE
REQUIRED TO GET
RID OF BUMPS, DENTS
AND BREAKAGE
OF
VARIOUS
USE
TECHNIQUES
AND
TOOLS

PANEL
BEATING
EQUIPMENTS
HAMMERS
DOLLYS
PULLERS
HACKSAW
BRUSH
CUTTERS
SCRAPERS
FILES

GETTING RID OF RUST

With rust proofing, one will need to
know how and why rust occurs so you
can effectively prevent it and get rid
of it when it forms on any body part.
You will also learn about the many
products and techniques that are
involved with rust removal and rust
inhibiting.

CUTTING & WELDING

Welding means using heat to attach two

pieces of metal.
Heat can be generate , Either gas or
electricity.
Many Types of welding available in market
Gas welding (oxy-acetylene welding),
Spot welding
MIG welding
TIG welding.

GAS
WELDING
welding can be done by
heating of both panels.
Flame is required to heat
the panels
Flame can generated by
combustion
of
acetylene with oxygen.
welding can be done
with or without the use of
filler metal.
Gas welding is most basic
and commenly used method
of welding in automotive body
reair shop.
Gas welding is used to cut
the metel as well to joint the
matel panels

SAMPLE GAS WELDING

SPOT
WELDING
Contacting metal
surfaces are joined
by
the
heat
obtained
from
resistance
to
electric
current
flow.
electrodes are
required
used to joint
sandwich
panels
as well as other
body joints.

SAMPLE SPOT WELDING

MIG WELDING

(metal inert gas welding)

Provides uniform weld bed

Semi automatic welding process
Long welding can be achieved without
intervals
Wire is continuously fed from a spool.
Argon or helium gas is used to
generate heat

TIG WELDING
(tungsten inert gas welding)

Used to weld thin metals

High quality and superior weld can
be achieved
An arc is formed between a non
consumable tungsten electrode and
the metal being welded.
Gas is fed through the torch to shield
the electrode and molten weld pool.

JACK & PULLER

WITH CAR ALIGNER

COMPUTERISED BODY
ALIGNMENT SYSTEM
By using the specially
designated
jigs
it
can
simultaneously correct body
damage
and
control
realignment
by
accurate
measurement
of
critical
dimensions. The car is then
reassembled
on
the
alignment system, thereby
ensuring
restoration
is
completed to the original
manufacturers specifications
and tolerances.

MIRACLE DENT REMOVING

SYSTEM

VEHICLE UNDER REPAIR

DEMO SEQUENCE
OF
REMOVING
CRITICAL DENT
FROM BODY PANEL

DENT ON VEHICLE

CUTTING BACK BACK PANEL

REPAIR OUTER PANEL FROM

BACK

PANEL BEATING WITH DOLLY

& FILE

INSPECTION & FINISHING

WORK

PULLING & FIXING OF

PANELS

INSPECTION & ERROR

REMOVING

PREPARATION OF RE
JOINTING OF PANEL

RE JOINT PROCESS IS ON

RE JOINT IS ALMOST DONE

PANEL READY FOR PAINT

JOB

ACKNOWLEDGEMENT
Special Thanks to,
1. Insurance Surveyor Association, Surat
M/s Weltech Motors, Surat
for providing opportunity.
2. Mr. Samir Joshi,
Mr. Narendra Panwala,
Mr. Vimal Joshi
for their valuable guidance in
making this presentation.

THANK YOU