CRR 325 - Sheet Metal Fundamentals

1. Identify and take necessary precautions with hazardous operations and materials according to federal, state, and local regulations
   1. Identify safety and personal health hazards according to OSHA guidelines and the “Right-to-know Law”
   2. Select and use the NIOSH approved personal sanding respirator. Inspect condition and ensure fit and operation. Perform proper maintenance in accordance with OSHA Regulation 1910.134 and applicable state and local regulation
   3. Select and use personal safety equipment, hand eye, ear, and respiratory protection
   4. Select and use the recommended proper protective clothing and footwear
   5. Use hammer and dolly to rough contour
   6. Use pick hammer to bring up small low areas
   7. Use file to eliminate surface irregularities
2. Vehicle construction and welding requirements
   1. Understand general vehicle construction for full frame and uni-body vehicles
   2. Describe proper heating techniques and general vehicle manufacture requirements for heating of metal throughout the metal repair process
   3. Describe proper welding techniques used for repairing Mild, HSS (high strength) and HSLA (high strength low alloy) steel
   4. Use water to cool panel
3. Straighten and rough-out contours of damaged panels to a suitable condition for body filling or metal finishing using power tools, hand tools, and weld-on pull attachments
   1. Determine direction of impact
   2. Plan the order of repair
   3. Locate and reduce surface irregularities on damaged body panel
   4. Demonstrate hammer and dolly techniques
   5. Metal finish selected areas of repair project
   6. Demonstrate proper grinder techniques
   7. Heat shrink stretched panel areas to proper contour
   8. Cold shrink stretched panel areas to proper contour
   9. Identify and repair a gouge, tear, and puncture in sheet metal
   10. Remove paint finish
   11. Determine the proper metal finishing techniques for aluminum
4. Metal Welding procedures
   1. Identify weldable and non-weldable materials used in collision repair
   2. Clean and prepare the metal to be welded, assure good metal fit-up, apply welding through primer if necessary and clamp as required
   3. Determine the correct GMAW (MIG) welder type, electrode, wire type, diameter, and gas to be used in a specific welding situation
   4. Determine the type of weld (continuous, butt weld with backing, plug, etc.) for each specific welding operation
   5. Determine work clamp (ground) location and attach
5. Select and apply filler material
   1. Mix body filler
   2. Demonstrate proper mixing equipment and application technique
   3. Apply body filler, shape during curing
   4. Identify and use varying abrasive grits to shape, finish, and featheredge filler
   5. Rough sand cured body filler to contour; finish sand
   6. Determine applications of body filler to aluminum
6. Preparation of filler, metal surface, and surrounding area for primers/surfacers
   1. Dry or wet sand areas to be refinished
   2. Featheredge damaged areas to be refinished
   3. Define time frame for application
7. Display ability to shape and contour plastic filler
   1. Use cheese grater file to rough shape plastic filler
   2. Use varying grits of sandpaper to shape, featheredge, and finish plastic filler