This can be used for repair to bodywork,and isextremely good on convex or concave surfaces where access with a disc sander would be difficult. This type of machine uses an endless sanding belt,which is 3in (16.1mm) wide,instead of the normal...

This is the most popular sander. It is a powerful machine with a hard rubber flexible pad on to which the actual sanding disc is fastened by means of a centre nut. This nut is threaded in such a waythat it tightens as the machine rotates,th...

Whether they are disc,belt,orbital,flat or finishing, sanders are the most frequently used power tools in the body repair shop....

This is a hand-held clamp-type drilling tool designed for cutting out spot welds (Figure 3.54). It is powered by compressed air with controllable speeds,and has a removable cutting drill supplied in two sizes,6mm and 8mm; the depth of cut i...

This uses an energy pack to supply the power,with a fast charge facility for recharging from a mains supply (Figure 3.53). It can be single speed or two speed,and can drill up to 3mm steel. When fitted with a reversible adjustable clutch th...

There are two types of power drill used in the bodyshop:the majority are usually electrically driven and require a 13A electrical power point (Figure 3.50),while the others are air powered and require a compressor and air points (Figure 3.5...

This is a high-speed pneumatic tool using interchangeable,reciprocating hacksaw blades (Figure3.48). It is able to cut from straight lines totight curves. Cutting can be started anywhere on a panel without the need for pilot holes. Single-...

This is a portable nibbler which uses a punch and die (Figure 3.47). The actual cutting is done by the edge of the punch which is reciprocated at high speed,leaving a slot or channel in the metal. Cutting can be commenced from the panel edg...

This tool uses the same action as snips,having twofixed blades and one blade moving vertically between them (Figure 3.46). This central movable blade cuts out a thin ribbon of metal which coils and is discarded. Cutting can be started from...

These are usually electrically operated (Figure 3.44),but in some cases can be driven by compressed air (Figure 3.45). They are designed to be used in the hand with an on/off trigger control built in the handle. The blade holding shoe is de...

This tool (Figure 3.43) is designed for the removal of damaged panels so that essential stripping can be carried out easily and quickly. It consists of a chisel bit which is retained by a spring through one end of a barrel,and a piston whic...

Choosing between pneumatic or electric power tools has always been difficult because,while they are designed to perform basically the same func- tion,the particular advantages and disadvantages of each are so different. Electric tools are s...

A cabinet-type toolchest as shown in Figure 3.41 is standard equipment in most body shops. A portable toolbox on top of the chest holds large hand and power tools. A chest of drawers holds spanners, sockets and all the necessary assembly to...

A variety of threaded fasteners used in the auto- motive industries are assembled by the use of a screwdriver. Each fastener requires a specific kind of screwdriver,and a body repairer should have several sizes of each type. All screwdriver...

In many situations a socket ratchet is much faster and easier to use than an open-ended or ring spanner because of its versatility in use,and in some body repair applications it is absolutely essential. A basic socket ratchet set consists o...

A complete collection of spanners or wrenches is indispensable for the body repair worker. A variety of vehicle body parts,accessories and related parts all utilize common bolt and nut fasteners as well as a range of special fasteners. The...

Having the right tool for the job is a sign of a prepared body repair worker. Knowing how to usethe tool is a mark of an experienced repair worker. Knowledge and experience come with study and time,but without the right tools,even the best...

This is a versatile sheet metal working tool,and will quickly and easily pull curved shapes into steel up to 18 gauge (1.2mm) or aluminium up to 14 gauge (2.0mm) (Figure 3.34). It shrinks or stretches the metal into smooth even curvature wi...

This tool is designed for bench mounting or to beused in a vice (Figure 3.33). The fixed rollers produce a smooth,uniform stepped panel edge on a straight or curved panel. The bottom roller is adjustable to accept varying gauges of material...

This is a small,compact folder constructed anddesigned for mounting in a vice (Figure 3.32). It can be used to fold mild steel sheet up to 1.2mm (18 gauge) with a bend length of 24in (610mm). The tool is capable of producing bends of up to...

This is a drill attachment for cutting sheet metal upto 18 gauge (1.2mm) mild steel and 16 gauge (1.6mm) aluminium (Figure 3.31). This tool pro vides the user with clear visibility of the cutting line,allowing an accurate cut. When cutting...

This is a lightweight metal shear (Figure 3.30) which will produce curved and straight cuts in mild steel up to 1.6mm (16 gauge). A lever andratchet action operates the roller cutters,which are adjustable for metal thickness,and the cutting...

The hacksaw is used by the body repair worker toadvantage where a clean,neat cut is required, usually where two pieces have to be cut to form a welded joint,and is ideal for cutting irregular- shaped panels which could not be cut with snips...

These are often used by the body repair worker for cutting out components which have been damaged, chipping off rusted bolts which cannot be removed by normal methods,and chiselling sections which cannot be cut be snips or hacksaws. Chisels...

This tool is designed for cutting thin sheet metal. Unlike snips,it has a flat face with one central serrated blade which in use cuts a slot equal in width to the thickness of the blade,about 1/8 in (3.1mm). As the material is cut,it coils u...

A rivet set is made of tool steel. A deep hole in the bottom of the set is used to draw the rivet through the metal sheet before riveting,and a cup-shaped hole is used to form the finished head on the rivet. The drawing-up hole and the cup...

The hand groover is used when making a seam joint by hand between two pieces of sheet metal. The end of the tool is recessed to fit over the joint formed when the edges of the two pieces of metal are prebent into a U-shape and interlocked. T...

Quite often when making panels and parts of panels in sheet metal,it is necessary to perform some operation such as bending,flanging,seaming,shaping and planishing which cannot be done by machine. In such cases these operations will have to...

Sandbags are leather bags made from two pieces of the finest quality leather,filled with very fine sand and stitched together. They are available in a variety of weights and sizes but are usually round or square in shape (Figure 3.27). The s...

Mallets (Figure 3.27) come in two shapes. Round-faced mallets These are used in conjunction with steel stakes forforming and shaping. There are two types of mallet boxwood and rawhide. The latter is made in strips which are rolled and pinne...

The panel beater often finds the need to fabricate articles or components in mild steel,using specialist hand tools. This need usually arises when replacement panels and sections are not readily available. These specialist tools are also fr...

The pride of the craftsman is the set of tools he possesses. Care of tools throughout their working life is important. All bright surfaces should be kept clean and free from scours and blemishes that could be transferred to the body panels....

Panel puller This tool (Figure 3.12) comprises a long steel rod with a cross T-piece at the top which acts as a hand grip. At the other end a fixed hexagonal nut holds a strong self-tapping screw,while a heavy cylindrical weight can slide u...

The offset combination of universal snips is preferred by the panel beater when cutting thin gauge metal. Universal snips (Figure 3.11a,b) are suitable for cutting straight lines,outside and inside curves. A right- and left-hand pair of comb...

Flexible panel file This tool (Figure 3.10a) is designed with a two position handle,and has a 14 in (30cm) spring steel backing plate to give adequate support over the whole blade. Positioned between the two hand grips is a turnscrew thread...

These tools are made from a high-grade steel which has been drop forged and heat treated. They are sometimes called prying spoons because the spoon end is used in the same manner as a dolly in conjunction with a hammer. The body spoon reall...

These are either cast or drop forged steel blocks, heat treated to provide the correct degree of hardness. The shapes of the dolly blocks have been designed to provide a working surface that is highly polished and suitable for use on the ma...

Planishing hammer The planishing or panel hammer is used more than any other tool in the body repair trade,and for thisreason the best hammer available should be obtained. The principal purpose of the panel hammer is for the smoothing and f...

Mass production methods have made the present-day motor car such that it requires special techniques,skills and tools for the rectification of body damage. Specialist tools have been designed to suit the varying contours and shapes of the p...

To protect yourself from the cleaning agents which you are using you must,where appropriate,wear personal protective equipment (PPE). Most cleaning agents are poisonous and cause irritation or more serious complaints if allowed to come into...

In your companys Health and Safety Policy document there will be reference to the cleaning of the floors and equipment in the garage and general amenities such as toilets and rest areas. Also there will be maintenance and repair records for...

The Environmental Protection Act (EPA) and local by-laws in most areas require that used cleaning solvents must be disposed of safely. This means that they must be put into drums and either col- lected by a refuse disposal firm or taken to...

Before using any solvent,detergent or sanitizing agent such as bleach you must read both the label on the container and the COSHH sheet which the manufacturer or your company has prepared. Solvent should only be used in the cleaning bath fo...

There are three main items of cleaning equipment used in the garage:the cleaning bath (or tank),the pressure washer and the steam cleaner. The cleaning bath uses a chemical solvent,this is usually used for cleaning dirty/oily components. Th...

You must always isolate an electrical machine from the mains supply before either cleaning it or carrying out any maintenance or repairs. There aretwo reasons for this:first,if you touch anelectrically live part you may get an electric shoc...

The Social Security (Claims and Payments) Regulations 1979 require employers to maintain an accident book as well as regulation 7 of the HSWA. This book requires brief details of any accident or dangerous occurrence to be recorded. An appro...

If you hear a fire/emergency warning you must follow the companys evacuation procedure this is usually stated on the workshop wall. If you hear a fire alarm a typical evacuation procedure is: 1.Shut off the electricity by pressing the emerg...

There are five different types of fire extinguishers in common use in garage premises,these are identified by their colour,as given in the following table: In addition there are fire bucketsfull of sand,and fire blankets. Before you use any...

Generally only senior staff (managers) are allowed to operate alarms and other forms of alert/evacua- tion systems. This is because of the costs which may be involved if the fire service is called out wrongly and the damage which may occur...

An authorized person is somebody who has thetask of carrying out a specific job. Anybody may call the emergency services if they are needed. The four emergency services are: Police Fire Ambulance Coastguard. All are called by dialling 999 o...