Wheel Base

It is the distance between the centers of the front and rear

axles (Dimension ` a ` )

1
 Wheel Track

• It is the distance between

the tyre centre at the

ground level when viewed

from front (Dimension` b ` )

Fig. 2

2
 Front Wheel Track

• It is the distance between

the front tyre centers at the

ground level when viewed

from front (Dimension` b’)

Fig. 3
3
 Rear Wheel Track

• It is the distance between

the rear tyre centers at

the ground level when

viewed from rear of the

vehicle (Dimension ` b’)

Fig. 4
4
 Ground Clearance

• It is the distance bottom most point of the body to the

ground level (Dimension ` c’).

Fig. 5

5
 Over all length
• It is the distance between the front and rear bumpers
(Dimension ` d’)

Fig. 6
6
 Over all Width

• It is the distance of the

body measured outside in

the width wise

(Dimension ` e’)

Fig. 7
7
 Overall Height

• It is the distance between

the point of wheel rest

and the top most point of

the body (dimension ‘f’)

Fig. 8
8
 Front Overhang

• It is the distance between the center of the front axle

and the front end of the body (dimension ‘g’)

Fig. 9
9
 Rear Overhang

• It is the distance between the center of the rear

axle and the rear end of the body (dimension ‘h’ )

Fig.10
10
 Interior Body Length

• It is the entire interior length of the body (dimension ‘I’ )

Fig. 12 11
 Interior Body Width

• It is the entire interior

width of the body

(dimension ‘j’ )

Fig. 13

12
 Interior Body Height

• It is the entire interior height of the body (dimension

‘k’ )

Fig. 14
13
 Door Height

• From the lowest footboard step to cant level (dimension

‘l’)
• It should be at least half of the overall height of the body

Fig. 15 14
 Door Width

• It is the width of the

opening provided for
entry/exit (dimension
‘m’ in fig)

• This should not be

less than 533 mm for
bus
Fig. 16
15
 Loading Height

• It is the distance
between the point of
wheel rest and the
floor of the load
carrying
compartment

16
 Gang Way

• It is the distance provided for the movement of the

passengers between two rows of seats

• This is also called as Aisle width

• It should not be less than 356 mm

17
 Dimensions of Buses

Specification in Leyland Leyland Tata Tata

mm Model 1 Model 2 Model 1 Model 2
Wheel base 5334 5156 5545 5195
Overall length 10245 9331 10090 8975
Overall width 2427 2427 2434 2434
Front overhang 1788 1158 1775 1185
Rear overhang 3124 3017 2770 2605
Front track 1918 1918 1915 1915
Rear Track 1816 1816 1752 1752
MinTunring circle d 20.80 20.10 20.06 20.30
18
 Dimensions of Cars

Specification Ambassador Premier Maruti Maruti

in metes Padmini 800 Omni 800
Wheel base 2.46 2.34 1.840 2.175
Overall length 4.343 3.93 3.280 3.300
Overall width 1.651 1.46 1.395 1.405
Overall height 1.6 1.468 1.395 1.405
Front track 1.359 1.232 1.205 1.215
Rear track 1.346 1.215 1.190 1.200

19
 Quiz

1. The distance between the center of the front axle and

the front axle end of the body is known as

a) Gang Way

b) Front Overhang

c) Rear Overhang

d) Wheel base

20
 Quiz

2. The distance between the centers of the front and rear

axles is called

a) Wheel base

b) Wheel track

c) Ground Clearance

d) Front overhang

21
 Quiz

3. The distance between the front and rear bumpers is

a) Overall width

b) Overall height

c) Overall length

d) Interior body length

22
What is the purpose of doors in Vehicles?

23
 Door
window
Window
winding
handle Door lock

Door trimming

Inner panel

Fig 1

24
 Constructional Details of Door

• It consists of inner panel, outer panel , window

winding mechanism, door lock and handles and
weather strip

• In fiat cars all doors are hinged on the central pillars

• In delight models the rear doors are hinged on central

pillars and front doors on front pillars

25
Panels of Doors

Fig 2
26
Panels

• It composed of inner and outer panels

• Both being of steel construction

• Inner panel gives strength to the door

• Outer panel is shaped in such way that it

conforms to the counter of the body

27
Weather Strip

• Door is sealed against body opening with rubber weather strip

Door Trimming

• It consists of large square board covered with selected cloth and leather, the
whole being assembled to the door frame
• Garnish rail cover the top of this panel below the window

28
Purpose of Door
• Enter and leave from the vehicle body

Location
• Arranged on sides and back of the vehicle
• Used 2 to 6 number of doors used in various vehicles

29
Types of Doors

1. Hinged doors
2. Sliding doors
3. Hatchback doors
4. Gull wing doors
5. Scissor doors
6. Butterfly doors
7. Suicide doors

30
Hinged Door

Fig 3

31
 Hinged Door
• Hinged on the Front edge

• This Arrangement makes it easier for a person in the seat to exit the car

• These are two types closed style and convertible style

32
Sliding Door

Fig 4

33
 Sliding Door

• Opens horizontally by sliding

• Do not require outside space for opening

• Suitable for entry to the occupants in busy areas and

traffic roads

• Arranged side of the car

34
Hatch Back Door

Fig 5

35
 Hatchback Door
• The door opens right from the floor

• Arranged at the rear side of the car

• Top –hinged tailgate or large flip-up window

• These are having 3 doors (2 entry and one hatch) or five doors ( 4 entry
doors and one hatch)

• Facilitates loading and unloading of bulky luggage more conveniently

36
Gull-wing Door

Fig 6
37
 Gull-wing door

• Hinged at the roof rather than the side

• They wouldn’t provide adequate protection and side-impact accidents

• Water sealing is more difficult because of the shape and movement path
of the door

• Expensive design

38
Butterfly Door

Fig 7

39
 Butterfly Doors
• They merely tilt forward and up and also rotate as
they move forward

• It is used in high-performance automobiles

• Get in and out of the car more quickly than conventional and gullwing doors

40
Scissor Door

Fig 8

41
 Scissor Doors
• Doors rotate vertically at a fixed hinge near the end of the windshield

• The hinge in a similar location as a conventional door

• These are also called as lambo doors, beetle-wing doors and switch
blade doors

• Door still impedes access/egress much more than gullwing

• It is used in high end super cars

42
 Suicide Doors

Fig 9 Fig 10

43
 Suicide Doors
• Hinged on the trailing edge

• Increased danger of the door falling open if it becomes unlatched

while the car is moving

• These are also called as coach door

44
 Quiz
1.In the passenger car doors are hinged to the

(a) Side pillars

(b) Scuttle

(c) Floor

(d) None of the above

45
 Quiz

2. Outer and inner panels both are being made up of

a. Plastic

b. Steel sheet

c. Wood

d. Leather

46
 Quiz

3.Sliding doors are used in

(a) Ambassador cars

(b) Maruti omni cars

(c) Hyundai cars

(d) Tata cars

47
What is the purpose of the window?

Admit natural light and allow inflow of air

when opened.

48
Purpose of Window:
• Admit natural light and allow inflow of air when opened

Location :
• Openings are provided in the upper part of the door
• It is regulated between Garnish and waist rails
• Opening is usually closed with on piece of glass

49
Types of Windows:

1. Slide across windows

2. Wind down windows

50
 Sliding Window
Sliding glass

Fig.1

51
 Sliding Window

• It consists of a two sliding glasses

• Mounted in metal frames

• Either of the glass can be slide to open

52
Wind down Windows

Lift type
glass

Fig.2
53
 Wind down Windows

• Window glass can be raised or lowered with

window winding mechanism

• These are commonly used in all cars

54
window regulator mechanism:

Purpose:
It is to raise or lower the window glass
easily

Location:
Mechanism is incorporated inside the door

55
 Window Regulator Mechanism

WINDOW
REGULATOR
HANDLE

Fig.3

56
 Window Regulator
Glass

carrier

Winding handle

Toothed
quadrant
Parallel arms
Fig.4
57
Window Regulator

Fig 5

58
 Window Regulator Assembly

Fig.5

59
Constructional details of window regulator:

• It is operated manually or electrically.

• It consists of winding handle , a smaller gear, tooth

quadrant, two parallel arms and a carrier.

60
 Operation of window regulator:

• As the winding handle is rotated gear turns

the toothed quadrant .

• Then toothed quadrant in turn operated parallel arms.

• These parallel arms raise or lower the window

carrier.

• Along with carrier glass is raised or lowered

61
 Quiz

1.The window winding mechanism should lift the glass of

the window squarely to avoid
(a) turning

(b) Slipping

(c) turning

(d) jamming

62
 Quiz

2. Winding handle rotates a gear to turn the

(a) toothed quadrant
(b) Carrier
(c) parallel arms
(d) None of the above

63
 Quiz

3 .Sliding doors are used in

a. Ambassador cars
b. Maruthi vans
c. Hyundai cars
d. Busses

64
 Quiz

4. Glass is located between

(a) Garnish rail and waist rail

(b) cant rail and garnish rail

(c) waist rail and cant rail

(d) two cant rails

65
 Quiz

5. Purpose of window is to

(a) admit natural sunlight and air

(b) cooling of engine

(c) heating of engine

(d) none of the above

66
 Seats
The journey will become pleasure trip with comfortable
seats. The trip becomes, agony and tiring with
uncomfortable seats

67
 Requirement of Seats
It should

• Damp vibrations in the vehicle structure

• Allow air to circulate around the body to avoid sweating

• Have above 900 angles between squab and seat cushion

to avoid thigh pressure on the stomach

• Provide angular positions of legs and foot work

68
 Requirement of Seats

Provide more suitable head for visual work

Provide safety

Not have too much inclination of back rest because

human eye will perform best when it is in inline to the
object being viewed

69
 Driver’s Seat

The basic design criteria to kept in mind while designing

driver’s seat are

The seat should position the driver with unobstructed vision

and within reach of all vehicle controls

The seat must accommodate the driver’s size and shape

The driver’s seat should be adjustable 45 mm horizontally

and 30 mm vertically

70
 Driver’s Seat

• The seat should be comfortable for extended period

• The seat should provided a safe zone for the driver in

accidents

• Driver’s seat must be sufficiently rigid to ensure the thrust

applied on back rest while braking

71
 Types of Seats

1. Bucket seats
2. Reclining seats
3. Child safety seats
4. Bench type
5. Anti-Submarine seats
6. Folding and split type
7. Side shift Aisle seats

72
 Bucket Seats

Fig.1

73
 Bucket Seats

• A bucket seat is a seat contoured to hold one person

• Small in size compared to bench type seat

• It is suitable for lack of seating room due to the

presence of a floor mounted shifter and parking
brake lever

• These are used in Maruti and Lancer cars

74
Side Shift Aisle Seats

Fig.2
75
 Side Shift Aisle Seats

• A space for walking with row of seats on either side or

with rows of seats on the sides

• Such as used in Luxurious buses

76
Anti-Submarine Seats

Fig.3
77
 Anti-Submarine Seats

• These are an extra thick front squab to protect the

driver and passenger in the event of a collision

• They are preventing the driver and passenger

from sliding forward

• Used in Martiz, Fiat sienna etc

78
 Reclining Seats

Fig.4
79
 Reclining Seats
• Back rest can be reclined which supports their head
when they nod off

• Used in Cielo GLE, Lancer cars etc

80
 Child Safety Seat

Fig.5
81
 Child Safety Seats

• Reduce the risk of injury in the event of collision

82
 Bench Seat

Fig.6
83
 Bench Seats

• This seat featured a continuous pad moving the full width

of the cabin

• The second row is usually a bench

• With this seats transmission shifter is move to steering

column and emergency brake lever is activated by pedal

• These are used in Chevrolet Impalla, Toyota Avalon cars,

and Ford crown cars, Ambassodor car, Premier padmini
cars
84
 Split and Folding type Seat

Fig.7
85
 Folding and Split Rear Seats

• They can be folded or splitted into half to provide

easy loading for even the most inconvenience luggage

• Folding rear seat has been provided Maruti 800 standard

model

• The split type (rear seat) usually used on luxury cars

86
 Quiz
1.Reclining seats are provided in
(a) Long distance vehicles
(b) Short distance vehicles
(c) Medium distance vehicles
(d) None of the above

87
 Quiz
1. A bucket seat is a seat contoured to hold ________ only
one
2. Side person
shift Aisle seats are used in _______________
Luxurious Buses
3. Anti-Submarine seats are preventing the driver and
sliding forward
passenger from _________________
4. Child safety seats are used to reduce ______________
in the event of collision the risk of injury

88
 Seat Construction

Seat back rest

Seat cushion

Figure. 1
89
 Seat Construction

• Seats of a car can be either single bucket seat or full

bench type design

• Both the types are constructed from two main parts

- Seat cushion
- Seat back rest (squab)

• The seat back rest is a two door Automobile, hinged

to swing forward, to allow access into back rest

90
Seat Construction

• It consists of springs, layers of padding, foam rubber

metal frame and upholstery cover

• The under seat space is filled by number of coiled

springs located at equal spacing throughout

• The springs on some seats are replaced with a flat

piece of rubber is called rubber insert

91
 Seat Construction
• It is then over laid with foam rubber

• The upholstery cover is pulled tightly over the

foam and is fastened to the seat frame

• The same is mounted on steel tubular frame to

constitute an assembly seat

92
 Seat Construction

• The rear seat cushion and back rest are of the

same basic construction as like front seat, but
uses lighter frame

• In Hatch back design, the seat back rest can be

folded to enlarge the cargo area

93
Seat Adjustments
Tilt
Head rest

Forward
Back seat

hinge

Rail

Seat cushionFigure. 2
94
 Seat Adjustments

• Numerous adjustments are possible in the seats for the

convenience of the driver and occupants
• These adjustments may be done linearly and angularly
such as
- Forward and backward adjustment i.e. 2 way
adjustment

95
 Seat Adjustments

• Forward, backward and slide (left and right) adjustment

i.e. 4 way adjustment

• Height and tilt adjustment along with forward

• Backward and side movements i.e. 6 way adjustments

96
 Seat Adjusting Mechanism

squab

hinge
Seat
cushion

Release
lever

spring
floor Fixed rail
pawl runner
Female runner
Figure. 2 97
 Seat Adjustment

Figure. 3
98
 Seat Adjusting Mechanism Construction

• The driver seat should be adjusted towards and away from

the steering wheel and control panel in order to suit drivers
of varying lengths of legs

• It can be done manually or electrically

• Seats are generally supported on steel channeling of top

hard section

99
 Seat Adjusting Mechanism Construction

• The rails of which are bolted to the floor panel

• Seats are mounted on male and female runners which

provide fore and aft movement

• The fixed runner member has ladder like slots cut down
on its top face

100
 Seat Adjusting Mechanism
• Release lever and pawl pivoting on the moving runner

• If the adjustment is necessary the release lever is pushed

down

• This frees the sliding runner and seat so the it can be

move fore and aft to selected position

• The lever is released so that the spring loaded pawl

snaps into one of the fixed runner slots

101
 Quiz

1.Seat consists of
(a) Seat cushion and seat back rest
(b) Squab and panels
(c) Seat cushion and panels
(d) None of the above

102
 Quiz

2. In seat adjusting mechanism release lever

and pawl pivots on
(a) Fixed rail
(b) Floor
(c) Moving runner

(d) None of the above

103
 Quiz

Coil Springs
3. The under seat space is filled by number of ____________

4. The springs on some seats are replaced with flat piece

of rubber is called _______________

Rubber Insert

5. The up holstury cover is pulled tightly over the foam and is

____________
Fastened to the seat frame

104
 Quiz

6. In hatch back design, the seat back rest can be folded to

enlarge____________
cargo area

7. Seat adjusting mechanism can be done either

_____________________
Manually or electrically

105
 Power Windows
• In ordinary cars the windows are opened and closed
manually

• In luxury cars they are operated electrically and are

called power windows

• In ordinary cars, each window is operated by an

individual lever

• But in power windows, Master switch is located on dash

board panel is used to close or open all windows
106
 Power Windows

• Individual switches on respective doors are also

provided

• These power windows are equipped with quality motors

• They operate quickly but silently

107
 Power Window
GLASS

ELECTRIC
MOTOR
LINKAGES

108
 Construction

• Master switch is located on dash board panel

• Individual switches provided on respective doors

• A small electric motor is attached to a worm gear and

several other spur gears

• Create a large gear reduction

• Gives enough torque to lift the window

109
• The linkage has a long arm

• Linkage attached to a bar that holds the bottom of

the window

• End of the arm can slide in a groove in the bar as

the window rises

• On the other end of the bar there is a large plate

that has gear teeth cut in to it

• Motor turns a gear that engages these teeth

110
 Operation

• When the electric switch is ON, the electric motor

rotate the gear

• A small gear turn the teeth plate

• Then teeth plate operates the bar and other

linkages

• The linkage arm and bar lifts the window glass

111
 Advantages

• Operate quickly but silently

• Reduce the effort to lift the windows

• Operate with electric switch or remote control

112
 Power Window

Depending upon the requirements of different cars, the

power windows are manufactured with three different systems

1. Power window with scissors system

2. Power window with cable system

3. Power window with Flexible window cable

113
Cowl

• Bulk head and dash board of body

•Portion between passenger and engine compartment

Fascia

•Gauges are fixed in the panel at the front of the driver

114
Scuttle

• Panel between back of the bonnet and the windscreen

Sill

• Section below the door openings

• It supports the floor and pillar
• Combines the chassis and frame

115
Gangway

• Distance between two rows of seats

Hull

• Hold the passengers and goods

Hood

• Front and rear curved portion connecting roof with front

and rear wind screen

116
Cant Rail

•Longitudinal framing of the roof

Garnish Rail

•Side rail of the door frame

Screen Rail

•Situated either above or below the wind screen

117
 Quiz

1.Facia panel is a

(a) Dash board panel

(b) Door panel

(c) Cowl

(d) All of the above

118
 Quiz
2. In side rail of the door frame is

(a) Cant Rail

(b) Garnish rail

(c) Screen rail

(d) Scuttle

119
 Quiz
3. Distance between two rows of seats is called as

(a) Gangway

(b) Sill

(c) Squab

(d) Hull

120
 Quiz
4. Combines the chassis and frame is

(a) Facia

(b) Hood

(c) Gangway

(d) Sill

121
 Quiz

5. In ordinary cars the windows are operated________ manually

6. Power windows are operated ____________

electrically
7. Power windows are used in ___________

8. In ordinary cars, each window is operated by an

Luxury cars
_______________

individual lever

122
 Quiz

9. In power windows a ____________main

is provided
switch on
dash board to operate windows

10. In power windows ______ are used ________ the

windows
motors to operate
11. Power windows are operated _______ and______

Quickly silently

123
Roof

Figure .1
124
 Roof
Purpose of Roof

• It is a metal sheet to Protect the passengers/goods

from the rain , wind and sunshine

Location

• It starts at rear wind shield and continuous across

car to the front wind shield

125
 Construction of Roof

• The roof panel is welded to the side rails of the roof,

the rear window and windshield frames by spot welding

• Curvature given to it by the forming presses

• Small metal strips placed crosswise to the roof at intervals

along the inside surface

126
 Construction of Roof

• They stiffen the front and rear wind shield frames

• Drip moulding is a u-shaped channel. It provides a

passage for water to drain

127
Roofs are two types as per the construction,
they are

1. Closed roof - Fixed roof

1. Open roof - Non rigid type, folded & open type

top

128
 Slide part of roof

open
Hinge roof hinge

Car Car
front front

Main roof
Main roof

(A) Sliding Panel Type (b) Hinged Panel Type

Figure .2
129
Different types of roofs to serve specific purpose

1.Sunshine roof
i) Sliding panel type ii) Hinged type

2. Roof with solar cells

3. Folding fabric type roof or convertible roof
4. Permanent covering type roof

130
Boot

Figure .3
131
 Boot
Purpose

The space provided beneath the rear hood for

the purpose of keeping goods, belongings and
spare wheel etc

132
Trunk Lid

Figure .4
133
 Construction of Trunk Lid

• It provides cover for the trunk compartment

• It is attached to body with the help of hinges

• A rubber weather strip seals the opening when the lid

is closed

• Suitable locking arrangement is provided

• The lid is constructed by die and presses as per the

shapes required

134
 Construction of Trunk Lid

• It has inner and outer panels

• The inner panel acts as the reinforcement and provides

mounting locations for the hood lock and the hinges

• The outer panel is formed in such a fashion that it has the

blending effect with the contour of the fenders and body

135
 Construction of Trunk Lid

• The hinges are even provided with coil springs or torsion

bars thus holding it up when it is opened

• Bonnet is kept closed by a manually operated lock and

safety catch

136
 Bonnet

BONNET

Figure .5
137
 Bonnet (Engine hood)

Purpose

It covers the engine compartment and protects the

Engine from dust and water

138
Grill

Figure .6
139
 Grill

• It is trim portion which covers the front of the radiator

• It allows fresh air to flow to radiator

• Held in place by nuts and bolts

• In some vehicles bumper and grills are made as one

piece unit

140
 Quiz

1.The luggage boot is closed by a door called

(a) Bonnet

(b) Grill

(c) Roof

(d) Trunk lid

141
 Quiz

2. The purpose of roof is to protect the

passengers/goods from Rain, wind & sunshine
___________________

U shaped
3. Drip moulding is a _________ channel to provide
passage for water and rain

4. Permanent covering roof is the most commonly

all passenger cars
used roof in ________________

142
 Quiz

Trunk Lid
6. ___________ provides cover for the trunk
compartment

7. Trunk Lid is constructed by die & presses

___________ as
per the shape required

8. __________
Bonnet covers the engine compartment

143
 Introduction
• Most of the automobiles were developed from the early
horse drawn carriage

• The body was little more than a single seat, and very
little safety or protection from the weather was given to
the occupants

• The little body was made of solid wood panels in a “slab”

side design, like a wooden box.

144
Stanhope Steam Car

Fig 1
145
• The first metal panels were handmade or made by
simple sheet metal forming machines

• The manufacturers gradually changed their

manufacturing technique from that of handmade body
frames to machine-made, mass-produced parts

146
• The vehicles gradually became more stylish

• The bodies, the outer panels, and fenders all increased

in size and had greater curves and crowns incorporated
into their shapes

147
 Metal Stamping

• New methods were developed to form flat metal sheets

into any desirable shape

• The flat metal sheets were stamped to shape by special

dies held in large presses

• Dies are carefully machined from solid pieces of steel

• They are made as a set (male and female) and must fit
together, leaving just enough room between them for the
sheet metal

148
• The flat sheet of metal is placed between the two dies,
which are held in alignment and brought together by the
pressure from a huge hydraulic press

• First only relatively simple curves were stamped

• As the stamping technology further developed, higher

crowned and larger panels were made

149
• These new stamping processes brought about the
evolution of the all steel body

• The heavy wooden skeleton, or frame of the body was

replaced with many steel stampings

• These steel stampings could be made quickly and

accurately

150
• Each stamping was identical in both size and shape

• The various stampings and body-forming contour panels

were assembled and held in specially designed jigs and

fixtures to be welded together to form the steel body

151
Huge Stamping Press

Fig 2
152
 Panels

• Auto bodies are made of many sheet metal stampings

that are welded together into a solid unit.

• The basic body structure of all automobiles consists of

pillars or posts, headers, rails, and outer and inner
panels.

153
 Panel Strength

• Each panel stamping is designed to add strength and

rigidity to the assembled unit.

• The amount of strength in any stamping depends on the

metal’s thickness, size and shape.

154
 Panel Strength
• A large panel would not be as strong as a similarly

shaped smaller panel, and an outer fender panel would

be made from thinner metal than a main pillar or frame

rail

• The most important factor determining a panel’s strength

is its shape

155
 Panel Strength

• Whenever metal is forced to change shape by bending or

stamping, the reshaped areas are made stronger

• It become much harder to bend back, and the metal is

said to have become work hardened

156
 Panel Strength

• Flat metal sheet is very soft and flexible

• After being pressed into a shaped panel it has greater

resistance to further bending

157
 Crowns, Flanges, Pressed Ridges, and
Channels
• The curved shapes pressed into panels are referred to
as crowns, flanges, and pressed ridges and channels.

• Each one is purposely designed to add strength to the

body.

158
Pressed Ridges And Channels

Fig 3
159
Various Crowns

Fig 4
160
 Inner and Outer Panels

• The outer panels are the ones you see by looking at the
outside of the vehicle

• They give the body its contour

• Every outer panel will have some crown in it

• It is almost always a compound crown, with a very slight

crown running from front to back and a vertical shape
anywhere from a very high to a very low crown
161
 Inner and Outer Panels

• Flanges of various shapes are found along the fender

wheel openings

• Ridges and channels are often pressed into hoods and

deck lids to strengthen them

162
 Inner and Outer Panels

• The inner panels reinforce the body shell and provide

mounting locations for the various interior trim panels
and other connecting assemblies

• They are also strengthened by the many ridges, folds,

bends, and ribs pressed into them

163
 Inner and Outer Panels

• Both the inner reinforcing panels and the outer box-

forming contour panels are spot welded to box-shaped

pillars, headers, and rails, which form the main frame

164
 Quiz
1. In metal stamping each stamping was identical in
_______

a. Size
b. Shape
c. Both size and shape
d. none

165
2. The various stampings and body-forming contour
panels were assembled and held in

a. Dies
b. Jigs and fixtures
c. clamps
d. none

166
 Quiz
3. Auto bodies are made up of many sheet metal
stampings and they are welded together as a
___________
single unit

4. Flat sheet metal is _________and

very soft Flexible
___________

Contour
5. The outer panels gives the body its __________

167
 Quiz

6. The inner panels one strengthened by

___________________pressed
Folds, bends and ribs into them

7. Crowns, Flanges are purposefully designed

_______________
to add strength to the body

8. Each stamping was identical in both

_______________
size and shape

168
 Introduction

• Most of the automobile parts, panels, and bodies are

made from plastics

• Plastics are made from resins

• Resins are synthetic materials, chemically produced by

combining two or more different compounds using
various types of chemical or mechanical processes

169
 Types of plastics

There are two different categories of plastics

1. Thermosetting plastics
2. Thermoplastics

170
Thermoplastics

• These plastics will soften and melt when heat is applied.

We can reuse this plastic by the application of heat

171
Thermosetting plastics

With these plastics, once the part is formed and the resin

has cured its shape cannot be changed by heating

172
• The introduction of plastic to the field of body work has
made possible easier and more delicate styling, specially
for interior

• The designer can make use of the crystal clear type of

plastic for such application as horn buttons, radio and
other grills, instrument dials

• Interior trimming plastic sheets used for panels and seat

backs, are provided in a variety of colors and patterns
includes wood grains and fabrics

173
 Reinforced Plastics

• Apart from the normal molded plastic body parts, there is

an approach to the use of plastic resins reinforced, with
a fibrous material

• The growth of the use of this material is due to its

physical characteristics

174
 Reinforced Plastics

Advantages

• Light weight

• Considerable strength and flexibility

• Resistance to rust and corrosion

175
 Reinforced Plastics
Advantages

• Ability to produce complex shapes with simple tools and

moulds

• Ability to resist impact shocks

• Excellent thermal insulation properties

176
 Disadvantages

• Low shear strength

• Low ductility

• High cost of raw material

177
Method of Manufacturing Plastic Panels (FRP)

• FRP – Fiber Reinforced Plastics

• Obtain the resin, catalyst accelerator

• Obtain mat glass reinforcement wax polish measures,

mixing bowls, scales, brushes, and rollers

178
Method of Manufacturing Plastic Panels (FRP)

• Prepare the surface of metal panel by well clearing down

and polishing dry irregularities

• Cover the working surface with wax polish not too

liberally and then polish all with puff less duster

179
Method of Manufacturing Plastic Panels (FRP)

• Prepare the glass reinforcement by ceiling the size

required leaving enough for an over lap of one two

inches

• Mix the resin to the amount required

180
Method of Manufacturing Plastic Panels (FRP)

• Brush on the first coat of resin to cover the working

surface of the panel

• Dust out with a brush and then roll out with rubber
roller dipped in the chalk

• This method prevents the resin forms pitching up on

the roller, the object is to ensure that no air is trapped
in the resin

181
Method of Manufacturing Plastic Panels (FRP)

• Leave the panel fin one or two days to allow the resin to
harden and age

• Normal trimmings of the panel can be done with hack-

saw. Normal drilling of holder is accomplished with twist
drills

182
 Wood

Now virtually obsolete in vehicles body construction

Types

• Soft wood

Pine & spruce used for floor body work

• Semi hard wood

Ash and beech are used for body frame work

183
• Hard wood
Oak & chest nut are used for structural members

• Special timber
Walnut & mahogany are used for interior finishing

• Ply wood
Used for interior work, panels flooring & trim boards

184
• Steel sheets

• Used for roof, scuttle, doors and wings

• thickness of steel sheet range from 0.8 to 1.5mm

• Light alloy

• Aluminum used extensively

• It has less weight and give good shape

185
 Plastic

• It is used for delicate styling, dashboards and panels

• PVC is used for covers, door handles, trimming and
roofing

• Plastic composite materials

• Fiber Reinforced Plastic (FRP)

- It is used to make bumpers, dashboard etc.

• Glass Reinforced plastic (GRP)

- Cost of manufacturing is high
- Painting is not required

186
 Glass
It is used as Safety glasses. Types of Safety Glasses

• Toughened glass

- It is a single piece plate

-It cannot be drilled or cut
• Laminated glass

- It consists of 2 thin sheets of conventional glass with

thick film poly methyl butyrl inner layer between them
- Localized breakage at the point of impact thus not
hampering visibility
187
 Rubber

•Synthetic rubber is used in body building

•Resist to fuel and heat

Types of Rubber

Open cell Type: Used for seat and soft finishing inside the
body
Closed cell Type: Does not absorb water used for outside
sealing

188
 Adhesives

• Made from dissolved natural rubber are used with sulphur

• Araldite is used for cold gluing of leather cloth

• Glass plates are glued by butvar

Textiles

• Used for internal trim

• Cotton fabric is used for body work

189
 Quiz

1. F.R.P. is used in preparing panel and as well as

_______

a. Bus
b. Motor cycles
c. Car bodies

190
2. F.R.P. means _______

a. Fiber reinforced plastics

b. Reinforced panel
c. Reinforced body materiel
d. Reinforced plastic body

191
 Assignment

• Explain preparation of plastic body panels

192
What is spot welding ?
where it is used?

193
 Various Structural Members of an
Automobile Body
• A car body consists of various structural
members. They are

Floor board
Roof
Front cowl assembly
Center pillars
Roof rail supports

194
 Various Structural Members of an
Automobile Body
• A car body consists of various structural
members. They are

Rear window header

Wind shield header
Rein forced hinge pillars for doors
Bonnet
Boot lid

195
 Various Structural Members of an
Automobile Body
• A car body consists of various structural
members. They are

Box section pillars for wind shield

Strut tower
Apron left
Apron right

196
Different Types of Spot Welding Joints

Figure .1 197
 Types of Sheet Metal Joints

Figure .2
198
 Methods of Joining the Members

• The structural members are divided into two categories.

They are:

1. Major structure members like floor, roof panels etc.

1. Minor structure members like bonnet and grill etc.

199
 Methods of Joining the Members

• In manufacturing of automobiles the major structure

members are held in position by jigs and fixtures.

• The major members are then permanently joined by

means of spot and seam welding made at various

distances from each other.

200
 Methods of Joining the Members

• Minor members are those that are readily removable

because they are fastened in place with nuts and bolts, hinges
etc.

• The body work involves sheet metal operations that

require formation of joints between any two sheet metal.

201
Floor

Location

• It runs backwards from the toe panel to the backrest

assembly.

202
 Floor Constructional Details

Figure .3
203
 Construction
• It is assembled the various pillars, pillars and panels are joined to form
complete body.

• It is made up of three stamped sheet –steel panels.

• Front section to carry the two front seats .

• Centre section has a transmission tunnel .

204
 Construction

• Transverse strength is provided by box sections at right angle to

the transmission tunnel.

• The remaining areas of flat floor are ribbed below the seats and
in the foot wells to add stiffness.

• In order to give rigidity and prevent vibrations, the beads and

channels are pressed into each of the panels.

205
Floor Pan Assembly

• The floor of the body is usually assembled first and the various pillars, rails,

and panels are joined to it to form the complete body.

• The other body panels are added to floor pan assembly

206
Floor Pan Assembly
• The floor pan is made of three different stamped sheet metal panels.

• To reinforce the floor pan, capping strips are spot welded to it at various

locations.

207
Floor Pan Assembly

Fig 4

208
Cowl Assembly

• The cowl assembly is made up of many smaller panel stampings of steel.

• The wind-shield opening frame meant to accommodate the glass.
• The top outer cowl panel. It is even vented in some designs of vehicle in

order to allow fresh air to enter the car.

209
Cowl Assembly

Fig 5

210
 Cowl Assembly

• The dash board panel. It has different warning and indicating devices.

• The hinge pillars which are meant for fastening front door hinges and the
cowl side panels.

• The fire wall. It is insulated in such a way that it does not permit the engine
noise to get penetrated inside the body.

211
 Cowl Assembly

• The cowl assembly is normally welded to the rocker panels and floor pan.

The assembly is also made use of for supporting the accessories like the

wind shield wiper, steering Colum etc

212
Quarter Panels

• The outer contour-forming rear quarter panels for both four-door and two

door vehicles are spot welded at the front to their pillar and along the bottom

to the inner wheel house panel.

213
Quarter Panels

Fig 6

214
Roof Assembly

• If the vehicle is to be a four door sedan, the center pillars and roof rails are

then added to the assembly.

215
Roof Panel And Drip Moulding Construction

Fig 7
216
Quiz

1. During the manufacturing of the automobile the major body structural

members are held in position by
(a) Die

(b) Press

(c) Jig

(d) None of the above

217
Quiz

2. Floor is located between backwards from the toe panel

to the
(a) Backseat assembly

(b) Front seat assembly

(c) Side seat assembly

(d) None of the above

218
 Quiz

3.The floor of the body is usually assembled first

and various other members are joined to it, to
complete assembly
form_____________

three different stamped

4.Floor pan is made of__________________
sheet metal panels

Capping strips
5.To reinforce the floor pan,____________
are spot welded to it at various locations
219
 Trimming

Trimming is a process of

• Decorating or finishing
• Providing heat and sound insulation
• Fixing of some functional parts
• To increase the aesthetic appearance of
the vehicle after painting

220
 Classification of Trimming

Trimming is mainly classified into two types

• Interior Trimming

• Exterior Trimming

221
 Interior Trimming

• Light colors give the impression of a large

• Dark colour make it appear smaller

222
 Interior Trimming

• Interior trimming is a process of adding or fixing interior

trim parts for the interior finishing of a vehicle

• The aesthetic character of the interior of a vehicle is

determined by interior trimmings

223
 Exterior Trimming

• Exterior trimming is a process of adding or fixing exterior

parts may be decorative or functional to increase
aesthetic appearance of a vehicle after painting

224
 Interior Trimming

Fig.1
225
 Interior Trimming

Fig.2
226
 Exterior Trimming

Fig.3
227
 Exterior Trimming

Fig.4
228
 Interior Trimming Parts
The Interior parts may be decorative or functional
• Upholstery panels and covers

• Head lining

• Garnish mouldings

• Interior light

• Cloth hangers

229
 Interior Trimming Parts

• Center pillar linings

• Sun visor
• Wind cords
• Door/ Window Glasses
• Window regulating handles
• Door handles
• Arm rests

230
 Interior Trimming Parts

• Wind shields
• Instrument panel
• Glass weather-strip rubbers
• Seat belts
• Seat covers
• Kick panel lining

231
 Interior Trimming Parts

• Floor mats

• Step plates etc.,

232
 Quiz

Decorating or finishing
1) Trimming is a process of ____________________

Heat and sound insulation

2) Trimming provides ______________________

3) Trimming is to increase the aesthetic appearance

__________________
of the vehicle before painting

233
 Quiz

4. Light colours give the impression of a larger

_________,
size
where as dark colour give the impression of a
_____________
smaller size

5. Interior trimming is a process of adding

________________
interior trim parts

234
Why interior fittings are required?

To improve comfort and aesthetic

appearance of the vehicle

235
 Location of various
Interior trim items

Fig .1
236
 Interior Trimming parts-
Upholstery Panels

Fig .2
237
 Interior Trimming Parts- Interior Light

Fig .3 238
 Interior Trimming parts-Hangers

Fig .4
239
 Interior Trimming parts-Hangers

Fig .5
240
 Interior Trimming parts-Sun Visor

Fig .6 241
 Interior Trimming parts-Wind Cords

Fig .7 242
Window Glasses

243
 Window Glass

Fig .8
244
 Door Handles

Fig.9 245
 Arm Rests

Fig.10
246
 Instrument Panel

Fig.11
247
 Glass Weather Strip Rubber

248
Fig.12
 Seat Belt & Seat Covers

Fig.13
F 249
i
 Quiz

1. Garnish mouldings are _____________trim

metal or plastic
Frames
2. Instrument panel is made up of
plastic material
___________
persons
3. Seat belts are used to protect the _______in
case of accidents

250
 Quiz

4. __________are
Floor mats used inside the
vehicle for decoration
5. Sun
__________are
visors used to protect from
sun light
6. Glass weather strip rubber is used to
_________________glass
provide seal between and
window

251
 Exterior Trim parts
Exterior trim parts include
• Door handles
• Rear view mirrors
• Wiper blades
• Bumpers
• Deck lock
• Number plates

252
 Exterior Trim Parts

• Styling lines

• Vehicle name scripts

• Emblems etc.,

253
 Exterior Trim parts-Door Handles

Fig 1
254
 Rear View Mirrors

Fig 2
255
 Wiper Blades

Fig 3
256
 Bumpers

Fig 4
257
 Deck Lock

Fig 5
258
 Number Plate

Fig 6 259
 Styling Lines

Fig 7
260
 Vehicle Name Scripts

Fig 8
261
 Emblems

Fig 9
262
 Door & Quarter Panel Trimming

• Trim panels for both doors & Quarter panel consists of

hard fiber board, which is covered with trim material

• In some models there is padding between trim

covering and backing boards

• Some manufacturers use a moulded fiber glass or

plastic trim panel

263
 Door & Quarter Panel Trimming
Trim panels are fastened to the inner door and
quarter panels by
• Metal screws

• Spring clips

• Plastic retaining clips

• Their bonnet ends snap into matching holes in the

inner planes

264
 Door & Quarter Panel Trimming

• Special trim fasteners are removed by sliding a “vee”

notched tool or screw driver between the inner door
panel and the trim pad

• Pads are replaced by lining up the clips with the holes in

the inner panel

• Tapping the pad over the fasteners to drive them in

265
 Door & Quarter Panel Trimming

• The palm of the hand is used to drive in fasteners, as the

hard tool could make the pad covering

• A heavy paper or plastic cover is glued them in

• It acts as an insulator pad and prevents the water that

runs down the window glasses

266
 Quiz

1) Identify the Exterior trimming part

a) Center pillar linings

b) Door handles

c) Sun visor

d) Wind cords

267
 Quiz

2) Pickup the odd one

a) Bumper

b) Mirror

c) Emblem

d) Wind cord

268
 Quiz

3) Pickup the odd one out

a) Instrument panel

b) Roof lining

c) Deck lock

d) Seat belt

269
 Garnish Mouldings

• Garnish mouldings are metal or plastic finishing trim

frames which fit around and inside of the window

openings and along edges to hide a seam or

unfinished edge found in the interior

270
 Garnish Mouldings

• Garnish mouldings are not used on the doors of some

models

• Because the door frame and trim pad have been

designed to take their place

271
 Garnish Mouldings

• All the joints exposed to the atmosphere are sealed

properly with suitable self curing adhesive caulking
compound to prevent water & dust entering into joint

• The doors are also provided with wind cords for both
doors and body at the point of contact

272
 Garnish Mouldings
Head Linings

Fig 1
273
 Head Linings

• Head lining is a trim material

• Which used to cover the underside of the roof panel

274
 Centre Pillar Trim

• The Centre pillar trim is either a plastic panel or a

fibre board panel

• Which is covered with a material or a metal painted

panel

275
 Kick Panel Trim

• The kick panel is a plastic, fibre board or metal panel

that fits under the dash from the front hinge pillar to the

fire wall

276
 Dust Proofing

• Dust proofing is a process involved in trimming or

painting

• Which is used to prevent the entry of dust and water into

the vehicle body

277
 Insulation

The Insulation is to reduce the undesirable

factors like
• Noise
• Heat from engine

• Fumes from engine

• Vibrations.

278
 Insulation

Insulation can be classified as

• Thermal insulation

• Acoustic insulation

• The sheet metal body require both the insulations

279
 Thermal Insulation

• Thermal Insulation prevents heat from entering into the

body

• This is specially required to prevent engine heat from the

hood through the cowl panels

280
 Thermal Insulation

• Plastics have almost replaced by conventional material

like cork, felt for thermal insulation

• Polyvinyl chloride or foamed polyurethane is presently

used for thermal insulation

• These material are light weight

281
Thermal Insulation Applied to Passenger
Car

Fig 2
282
 Thermal Insulation

Fig 3
283
 Acoustic Insulation

• There are two problems with Acoustic Insulation

• The source of sound i.e. body panel, require damping

• Sound waves may be absorbed by suitable surface

applied to the body panel

284
 Acoustic Insulation
• Material with high elasticity are used to damp body panel
vibrations

• The damping effectiveness depends on their thickness

and mass

• Good damping may be obtained by spraying material on

the body panels

• This material also act as lining adhesive and also as

thermal Insulator
285
 Body Insulation of a Car (Wolseley)

Fig 4
286
 Quiz

1) Dust proofing is used to

a) Window openings
b) To prevent the entry of dust
c) Metal painted panel
d) Fiber board

287
 Quiz

2) Garnish mouldings
a) Which fit around the inside of the window
openings
b) Head linings
c) Kick panel trim

288
 Paints

• Paints can be defined as films employed to cover a

surface, offering protective and decorative coatings

• Paints are also used to control light and heat reflectance

• Bright colours reflect more light and heat than darker

colours.

289
 Painting

The purpose of painting

To protect from rusting

As a decoration

An identification of utility

290
 Painting Materials

To paint the body of an automobile the materials

required are

a) Primer

b) Putty

291
c) Paint
i) Nitro cellos lacquers

ii) Synthetic enamels

iii) Acrylic lacquers

iv) Acrylic enamels

292
d) Thinners

e) Reducers

f) Solvent

g) Metal conditioner

293
 Purpose and Function of the In-gradients

The non- volatile or film forming material remains in the dried form and are
made up of binders in pigment

The binder is that portion which acts as carrying medium for the pigment and
carries body of the painting toughness and glass to the film

294
 Purpose and Function of the In-gradients

The pigment is the colouring portion and serve to opacity as well as

protection quality to the binder

The main function of thinner is to make it possible to apply the film forming
material

295
 Various layers of Paint

The layers of paint may be classified into

a) Premier surface or primer coat

b) Top coat or finish

296
 Functions of the Painting Materials

Primer and primer coatings

• It is intended to provide adhesion for the color coat to
follow

• If primer coating is used, it will fill imperfections on the

metal surface

297
Putty
• It is used to fill deep scratches or dents on the surface of
the body

• It is usually be made of the same basic material as the

primer surface but heavier in solids

298
Paint
• Paint is the film forming material either by lacquers or
enamels mixed with solvent

• The base may be nitro-cellulose or acrylic for repainting

and touching the same type of paint is recommended

299
Thinners and reducers
• Used to solvents and correct viscosity of the paint for
sprayings

• Thinners are used for lacquers

• Reducers are used for synthetic base resins

300
Sealers
• Used for sealing down raw scratches when recoating
surface sealers are formulated from resins and when dry
are not easily soluble in the common solvents

• They act as a shield for material over which, they are

sprayed by preventing the penetration of the solvents

301
Metallic
• For the luminous quantity of the paint small metallic
flakes are mixed with the paint

• These are known as metallic paints

• These are very popular but the main problem is to get

same shade and reflective quantity

302
Metal conditioner

When the bodies are scraped to bone metal, rust will form very quickly. In
order to prevent the formation of rust, the metal is chemically cleared with
metal conditioner. This prevents the formation of rust by forming a coat

303
 Quiz

1. The purpose of painting the automobile body

a. To protect from rusting

b. As a decoration
c. An identification of utility
d. All of the above

304
 Quiz

2. Which one is the painting material?

a. Putty
b. Thinners
c. Solvent
d. All of the above

305
 Quiz

Film forming material

3. Paint is the ______________________mixed with
solvent

4. Paints are also used to _______________and

_____________ Control light

Heat reflectance
5. Bright colours reflect _______________and ______
than dark colours
more light heat

306
 Quiz

identification of utility
6. Paint is used as an _____________________

7. Paint is used as a _______________

decorative

8. Paint is to _________________
protect from rusting
9. Primer coating are used _________________________
on the metal surface
to fill imperfections

307
 Methods of Painting

a) Brush painting

b) Spray painting

c) Dipping method

308
 Brush Painting

• It is also called hand painting

• By using a brush the body parts can be painted by a

skilled painter

309
 Spray Painting

• After cleaning and degreasing, the body is dried for

painting

310
Spray Painting

311
Spray Painting

312
Spray Painting Gun

313
 Spray Painting Gun
• For spray painting a series of operations are

a) Primering

b) Putty application

c) Sanding

d) Putty touchup & tack ragged

e) Finish coat

f) Touching or repainting

314
 Primer Coat

• It is the process of spraying diluted primer or primer

surface of two coats with an air pressure of 3 to 3.5
atmospheres at an interval of 10 to 15 minutes between
the coats

• The primer is dried either by air-dry method or force dry

method

• Before force-dried, it is allowed to air dried for 15

minutes after the second coat

315
 Putty Application

• After drying the primer, apply putty wherever required

• Deep dents are to be filled progressively in three layers

at an interval of 2 hours

• After applying the final coat of the putty, allowed to air-

dry for a period of 8 hours

316
 Sanding
• After drying the putty, the putty is sanded with 220 wet
abrasive papers and water

• After that the whole body is sanded with 320 wet

abrasive papers

• Then wash thoroughly so that the surface must be free

from dust and dirt, then wipe with clean cloth and allow
drying up, either at room temperature or in an oven
maintained at 900 c to 1000 c for 5 minutes
317
 Putty Touchup And Tach Ragged

• All puttied portions are to be touched up with two coats of

diluted primer with 10 to 15 minutes interval

• The touched up portion and over-sprayed areas are to be

de nipped with 320 wet abrasive paper, then the body is
ready for painting

• Then the body id ready for painting

318
 Finish Coat
• Three coats of paint diluted with thinner is sprayed at an
interval of 5 to 8 minutes between coats

• After the final coat, it is allowed to air dry for 8 hours at

room temperature or it may be allowed to air-dry for 15
minutes and then force-dry at 800 c to 900 c for 15 to 20
minutes

• Then sanding may be done with 400 wet abrasive paper

using soap and water or white spirit
319
 Finish Coat

• After that spray, one more coat of paint is applied

• This is allowed to air-dry for 8 hours and then burnished

with water rubbing compound and finally polished with
car polish and cleaner

• The last coat of painting and polishing are generally

done after completing the mechanical work

320
Touching And Repainting

321
 Touching And Repainting
• The damaged portions are sanded down with 320 wet
abrasive papers and water wiped and dried

• Where bare metal is not exposed, spray two coats of

paint on the portion at an interval of 5 minutes between
the coats

• Take care to avoid over spray and dust collecting on

other areas by employing a lower pressure

322
 Touching And Repainting

• A mist coat of thinner is recommended around the

touched portion for proper merging

• If bare metal is exposed during sanding spray one coat

of primer, 3 coats of paint and one coat of finish spray,
must be done at the interval specified for new painting

• If a skilled operator does the spray painting according to

the correct procedure it offers a longer life

323
 Dipping Method

• In this method the body parts will be dipped in the paint

which is in a container

• After some time parts will be removed from the paint and

dried

324
 Removal of Old Paint and other Impurities
There are several methods in use to remove the old paint
Some of them are

1. Sand blasting
2. Applying hot caustic soda solution
3. Paint remover-chemical solution
4. Power sanding equipment
5. Disc grinder
6. Hand scrapping

325
Masking

326
Masking

327
 Masking

When painting an automobile body it is important to cover and protect certain

areas from paint over spray. This operation of covering the protected area is
known as masking

328
 Quiz

1. In the following the painting method is

a. Brush painting
b. Dipping method
c. Spray painting
d. All the above

329
 Quiz
2. The following is the spray painting
procedure

a. Primer coat
b. Putty application
c. Sanding
d. All the above

330
 Quiz

3. The operation of covering certain areas from paint is

called ______________
masking

4. In ______________process of painting, the body parts

are dippeddipping
in the paint, which is in the container

5. __________________is one the paint removing

equipment
Disc grinding

331
 Quiz

6. In finish coat, _____________of

three coatspaint with thinner is
sprayed at an interval of _________________between
5 to 8 minutes
coats

7. After finish coat, the body is allowed for air dry for
__________

8 hours

332
Paint Booth

333
Paint Booth

334
Paint Booth

335
Top Coat

336
Top Coat

337
 Company Painting Method

• Basically, there are 4 stages of painting process ; a

pre – treatment stage which is known as the 3-coat ,
rust prevention stage, the under coat stage

• The second coat stage for the purpose of enhancing

the appearance of the top coat stage

• For trucks, only two coats are applied during the

second-stage coat stage
338
 Company Painting Method

• The body painting process are

1. Decreasing and chemical treatment stage
2. Electro deposit painting stage
3. Second coat painting stage

339
 Company Painting Method

• The body painting process are

1. Top coat painting stage
2. Special painting
3. Final conformation & inspection
4. Touch –up stage

340
Degreasing and Chemical Treatment Stage

• In this stage, dirt and grease are completely removed

from the body panels and a zinc phosphate film is

formed to help prevent dust and assist adhesion of the

under coat

341
 Electro Deposit Painting Stage

• This is the stage in which the body is completely dipped

into ED paint so that the paint is applied evenly not only

on the panel surfaces but also to every joint and closed

section

342
 Second Coat Painting Stage

• Here the roughness of the base metal ED paint film is

corrected and 2nd coat is applied to upgrade the quantity

of the coat. In this coat, the engine compartment, and

instrument panel is given in a dirt coat and the door

frames are given a semi-gloss coating

343
 Top Coat Painting Stage

• In which the body surface is given its final appearance

finish. Body is painted with the automatic spray paint

system (or) electrostatic painting system

344
Top Coat Drying

345
Top Coat Drying

346
 Top Coat Painting Stage

• For drying the topcoat, combined usage is made of a

dark infrared, indirect heating system and a convention

current, direct heat system. Total drying time takes 25-70

minutes at 1400C

347
 Special Painting

• Body is to be given a paint stripe

348
 Final Confirmation & Inspection

• This inspection is primarily conducted to check the paint

specifications and if specification standards are met, the

body is sent to the assembly line

349
Automatic Paint Booth

350
 Touch-up Painting Stage

• Although the body is given an inspection after application

of the coat, it is possible that the paint finish can get

damaged or panel detent while on assembly line. If any

defects are found the body is brought to be second coat

stage, and repairs are carried out on the spot and once

again touch-up painting is done

351
Advantages of Paint Booth Method of Painting

1. Due to complete automation, environmental pollution is

less

2. Due to the usage of CNC machines and robots the paint

requirement is lesser than manual painting

3. Man power involvement inside the paint booth is totally

eliminated

4. Health hazards like Asthma, Aspiration problems and lung

cancer are totally avoided

352
Advantages of Paint Booth Method of Painting

5. Due to automation, the whole body is uniformly painted

in this process, drying is fast, because dryers are used

6. Collection of dust & dirt etc on the undried painting surface

is completely avoided

7. High quality paintings are possible due to automation

this method is best suitable for mass production

353
 Disadvantages of Paint Booth
Method of Painting

1. Intermediate checking during painting process is not

possible

2. Initial cost of the equipment is very high

3. Maintenance cost of the equipment is very high

4. Due to automation, man power is utilized only for

supervisory level

354
 Quiz

1. Four
Basically these are _______stages in the painting
process

2. Zinc
_______________is
phosphate film formed to help in preventing rust
formation

3. In electro deposit stage, the body is completely

dipped
____________in the ED paint.

355
 Quiz

The body surface

4. In top coat stage _________________is given its final
appearance

5. For during top coat, the body is kept in during chamber

1400C
maintains at a temperature of ________

6. Total during time for during the top coat is

25-70
___________minutes

356
 Quiz

7. In special painting stage, the body is given a

Paint stripe
____________________

8. Body coat paint specifications are checked in the

Inspection stage
_________________________

9. After insurrection stage, the body sent to

Assembly line
____________________

357
Central Door Locking

358
 Central Door Locking

• A door locking system normally locks all doors, including

the tailgate or boot simultaneously when the driver’s

door lock is activated. When the key is turned or the

driver’s door lock button is operated, the electrical

system actuates all the locking activators installed

adjacent to the door locks

359
 Central Door Locking

• Unlocking the door takes place in the similar way except

the locking actuators work in the opposite direction. Both

for convenience and safely reasons, a mechanical

latches system is fitted, which unlocks each door

manually from inside of the car

360
 Central Door Locking

• Various types of control are incorporated to provide the

locking/unlocking pulse for operation of the actuators. In

some designs two relays are used, one for locking and

the other for unlocking the doors

361
 Central Door Locking

• A transistorized switching circuit controls these relays.

The circuit is timed by the charge-discharge action of a

capacitor to provide a current pulse length sufficient to

actuate the locks

362
Door Locking Actuator (using reduction gear)

363
 Central Door Locking

• Now a days almost all door actuators use small motors

which, via suitable gear reduction, operate a linear rod in

either direction to lock or unlock the doors

364
 Central Door Locking

• A simple motor reverse circuit is utilized for the required

action. Figure 2 illustrates a typical door lock actuator

• More sophisticated systems are now becoming popular

for consideration of safety as well as improved comfort

365
 Central Door Locking

• The following features are now available from many

manufacturers

• One shot up or down

• Inch up or down
• Lazy lock
• Back off

366
Air Bags

367
 History of Air Bags

The airbag as known today was invented by John W. Hetrick

in 1952 and he patented the device the following year.
Hetrick came up with the idea to help protect his own family
using expertise from his naval engineering days

The device was briefly available in the United States in the

mid-1970. Ford built an experimental fleet of cars with
airbags in 1971. in 1973 Oldsmobile Tornado was the first car
with airbag intended for sale to public

368
 Air Bag Components

The 3 most important

components of an Airbag
are

• The Bag Itself

• Inflator

• Crash Sensor

369
 Construction and Working of Air Bags
The bag itself is made of a thin, nylon fabric, which is folded
into the steering wheel or dashboard or, more recently, the
door or seat

The sensor is the device that tells the bag to inflate. Inflation
happens when there is a collision force equal to running into a
brick wall at 10 to 15 miles per hour (16 to 24 km per hour). A
mechanical switch is flipped when there is a mass shift that
closes an electrical contact, telling the sensors that a crash
has occurred. The sensors receive information from an
accelerometer built into a microchip
370
 Working of Air Bags
In the airbag's inflation
system, Sodium-Azide
(NaN3) reacts with
Potassium Nitrate (KNO3) to
produce nitrogen gas. Hot
blasts of the nitrogen inflate
the air bag. the air bag and
inflation system stored in the
steering wheel
Even though the whole process happens in only one-twenty-
fifth of a second, the additional time is enough to help prevent
serious injury

371
 Safety Precautions regarding Air Bags
The force of an airbag can hurt those who are too close to it.
Researchers have determined that the risk zone for driver
airbags is the first 2 to 3 inches (5 to 8 cm) of inflation. So,
placing yourself 10 inches (25 cm) from your driver airbag
gives you a clear margin of safety

An airbag can seriously injure or even kill an unbuckled child

who is sitting too close or it is thrown toward the dash during
emergency braking

372
Types of Airbags

373
 Types of Airbags

• There are several types of airbags

• Most vehicles have airbags that deploy in frontal crashes

to protect front-seat occupants

• These airbags are stowed in the steering wheel for the

driver

• Frontal airbags for the passenger are stored in the

instrument panel
374
Working of Air Bag during an Accident

375
Working of Air Bags

376
Working of Air Bags

377
 Quiz

1. A door locking system normally locks all doors

the driver’s door lock is

when ______________________________
activated
2. mechanical latches system is fitted, which
unlocks_________________________________
each door manually from inside of the car

378
 Quiz

3. Now a days almost all door actuators use

small motors
____________________

4. A transistorized switching circuit controls

__________
various relays which are used in locking and

unlocking doors

379