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Aluminum Exterior Panel Repair and Replacement

Course format: Live instruction with posttest
I-CAR Credit Hours: 3 hours
Estimated Duration: 4 hours
Platinum: $114.00
Gold Class: $114.00
Standard: $138.00

Prior Recommended Programs

  • Adhesive Bonding (ADH01)
  • Removing and Installing Hardware Interior Trim (TRM02e)
  • Removing and Installing Exterior Trim, Pinstripes, and Decals (TRM03e)

This course helps satisfy ProLevel training requirements for the following roles:
Non-Structural Technician

This course meets New Technology training requirements for the following roles:
Production Management

This course is an Annual Training option for the following roles:
Production Management
Steel Structural Technician
Aluminum Structural Technician
Non-Structural Technician
Auto Physical Damage Appraiser

Learning Objectives

  • Explain how hardening changes the characteristics of aluminum
  • Describe how to use dye penetrant for locating damage
  • Reduce cross contamination between metals
  • Understand the importance of using dedicated tools for working on aluminum
  • Explain the requirements of working with adhesives
  • Describe how to hem a panel
  • Understand some considerations for welding aluminum
  • List the different processes used for removing damage in cosmetic panels
  • Describe the different aluminum panel attachment methods
  • Know how to prepare an aluminum surface for body filler and refinishing

Module 1 - Cosmetic Aluminum Panel Overview
The first module begins with an overview of where aluminum is used and its characteristics. Techniques and certain differences between repairing aluminum and steel are given. The module will also explore damage considerations, panel straightening, paintless dent repair (PDR) straightening techniques, and corrosion protection.

Planned student group activities will help reinforce learning and keep students engaged as the course continues with instruction on techniques to remove damage. Some of the techniques will include hammer and dolly use, using heat with aluminum, PDR, weld-on and glue-on dent removal, and preventing corrosion.

Module 2 - Attachment Methods
As the course continues, the student will receive demonstrations and explanations of several panel attachment and removal methods including, adhesive bonding, threaded fasteners, bolted-on parts, and rivet types and use. The students will also learn about preparation and application, including rivet bonding, hem flange removal, hemmed door skin replacement, welded exterior panel removal, and joint preparation. Aluminum welding considerations such as welding tears and dressing the weld will also be covered.

Module 3 – Surface Preparation and Refinishing
The course will conclude with surface preparation and refinishing considerations, such as prepping the surface for body filler, types of body fillers, primers, and refinishing aluminum parts.

Course outline containing topics and subtopics.