Big Sandy Community and Technical College. Course Syllabus

Transcription

1 Big Sandy Community and Technical College Course Syllabus PS Number: Semester: Fall Year: 2017 Faculty Name: Dewayne Kinner Title: Instructor Course Prefix and Number: CRT 131 Course Credit Hours: 6 Course Prerequisites: CRT 130 Course Title: Non-Structural Analysis and Damage Repair Lab Catalog Course Description: Provides practical experience in the replacement and alignment of bolts on automotive parts such as doors, hood, and fenders; as well as instruction on the repair and replacement of non-structural weld-on automotive panels by aligning, welding, cutting and drilling. Includes instruction on how to repair plastic, fiberglass, SMC and flexible automobile parts. Requires skills that are most effectively taught and practiced on live work; the exact content will be influenced by the live work available. Instructor Contact Information: Campus Location: Mayo Building & Room: 104 Office Hours: 7:30am-3:00PM Office Phone Number: Alternate Number: Best Times to Call: 7:30-3:30 KCTCS Dkinner0001@kctcs.edu Special Instructions: If a special need arises you may call my cell Supervisor Contact Information: Name: Dean Kelli Chaney Campus Location: Pike Building & Room: Front Office

2 Office Phone Number: KCTCS Text and Supplies: See attached tool and supply list attached to syllabi. KCTCS General Education Competencies Students should prepare for twenty-first century challenges by gaining: A. Knowledge of human cultures and the physical and natural worlds through study in the sciences and mathematics, social sciences, humanities, histories, languages, and the arts. Mathematics is a crucial tool used within the automotive trades. We will use math to calculate frame specifications and front end alignments. Also, the science of chemistry will determine paint type and color. B. Intellectual and practical skills, including inquiry and analysis critical and creative thinking written and oral communication quantitative literacy information literacy teamwork and problem solving Each lab exercise will require a student to analyze the damage each vehicle has sustained while in an accident. From there, the student will have to develop a plan for repairs C. Personal and social responsibility, including civic knowledge and engagement (local and global) intercultural knowledge and competence ethical reasoning and action foundations and skills for lifelong learning This class will help you develop troubleshooting skills that you will use throughout your entire career as a collision repair technician D. Integrative and applied learning, including synthesis and advanced accomplishment across general and specialized skills. The skills you obtain in this class are very specialized it is crucial that you attend class and make it a point to set time aside for studying and preparing for every meeting. Course Specific Competencies (Student Outcomes): Upon completion of this course, the student can: 1. Replace and align bolts on parts such as doors, hoods, and fenders.

3 2. Repair and replace weld-on panel. 3. Repair plastics, fiberglass, and flexible automobile parts. Lab Competencies (Student Outcomes): (Enter N/A if this does not apply.) NON-STRUCTURAL ANALYSIS AND DAMAGE REPAIR For every task in Non-Structural Analysis and Damage Repair, the following safety requirement must be strictly enforced: Comply with personal and environmental safety practices associated with clothing and the use of gloves; respiratory protection; eye protection; hearing protection; hand tools; power equipment; proper ventilation; and the handling, storage, and disposal of chemicals/materials in accordance with local, state, and federal safety and environmental regulations. A. Preparation 1. Review damage report and analyze damage to determine appropriate methods for overall repair; develop and document a repair plan. 2. Inspect, remove, store, and replace exterior trim and moldings. 3. Inspect, remove, store, and replace interior trim and components. 4. Inspect, remove, store, and replace body panels and components that may interfere with or be damaged during repair. 5. Inspect, remove, store, and replace vehicle mechanical and electrical components that may interfere with or be damaged during repair. 6. Protect panels, glass, interior parts, and other vehicles adjacent to the repair area. 7. Soap and water wash entire vehicle for inspection. 8. Prepare damaged area using water-based and solvent-based cleaners. 9. Remove corrosion protection, undercoating, sealers, and other protective coatings as necessary to perform repairs. 10. Inspect, remove, and reinstall repairable plastics and other components for off-vehicle repair. B. Outer Body Panel Repairs, Replacements, and Adjustments 1. Determine the extent of direct (primary) and indirect (secondary) damage and direction of impact; develop and document a repair plan. 2. Inspect, remove and replace bolted, bonded, and welded steel panel or panel assemblies. 3. Determine the extent of damage to aluminum body panels; repair or replace. 4. Inspect, remove, replace, and align hood, hood hinges, and hood latch. 5. Inspect, remove, replace, and align deck lid, lid hinges, and lid latch. 6. Inspect, remove, replace, and align doors, latches, hinges, and related hardware. 7. Inspect, remove, replace and align tailgates, hatches, lift gates and sliding doors. 8. Inspect, remove, replace, and align bumper bars, covers, reinforcement, guards, isolators, and mounting hardware. 9. Inspect, remove, replace and align fenders, and related panels. 10. Straighten contours of damaged panels to a suitable condition for body filling or metal finishing using power tools, hand tools, and weld-on pulling attachments. 11. Weld damaged or torn steel body panels; repair broken welds. 12. Restore corrosion protection. 13. Replace door skins. 14. Restore sound deadeners and foam materials. 15. Perform panel bonding.

4 16. Diagnose and repair water leaks, dust leaks, and wind noise. 17. Identify one-time use fasteners. C. Metal Finishing and Body Filling 1. Remove paint from the damaged area of a body panel. 2. Locate and repair surface irregularities on a damaged body panel. 3. Demonstrate hammer and dolly techniques. 4. Heat shrink stretched panel areas to proper contour. 5. Cold shrink stretched panel areas to proper contour. 6. Mix and apply body filler. 7. Rough sand body filler to contour; finish sand. 8. Determine the proper metal finishing techniques for aluminum. 9. Determine proper application of body filler to aluminum. D. Moveable Glass and Hardware 1. Inspect, adjust, repair or replace window regulators, run channels, glass, power mechanisms, and related controls. 2. Inspect, adjust, repair, remove, reinstall or replace weather-stripping. 3. Inspect, repair or replace, and adjust removable power operated roof panel and hinges, latches, guides, handles, retainer, and controls of sunroofs. 4. Inspect, remove, reinstall, and align convertible top and related mechanisms. E. Metal Welding and Cutting 1. Identify weldable and non-weldable substrates used in vehicle construction. 2. Weld and cut high-strength steel and other steels. 3. Weld and cut aluminum. 4. Determine the correct GMAW (MIG) welder type, electrode/wire type, diameter, and gas to be used in a specific welding situation. 5. Set up and adjust the GMAW (MIG) welder to "tune" for proper electrode stickout, voltage, polarity, flow rate, and wire-feed speed required for the substrate being welded. 6. Store, handle, and install high-pressure gas cylinders. 7. Determine work clamp (ground) location and attach. 8. Use the proper angle of the gun to the joint and direction of gun travel for the type of weld being made in the flat, horizontal, vertical, and overhead positions. 9. Protect adjacent panels, glass, vehicle interior, etc. from welding and cutting operations. 10. Protect computers and other electronic control modules during welding procedures. 11. Clean and prepare the metal to be welded, assure good metal fit-up, apply weld-through primer if necessary, clamp or tack as required. 12. Determine the joint type (butt weld with backing, lap, etc.) for weld being made. 13. Determine the type of weld (continuous, stitch weld, plug, etc.) for each specific welding operation. 14. Perform the following welds: continuous, plug, butt weld with and without backing, fillet, etc. 15. Perform visual and destructive tests on each weld type. 16. Identify the causes of various welding defects; make necessary adjustments. 17. Identify cause of contact tip burn-back and failure of wire to feed; make necessary adjustments. 18. Identify cutting process for different substrates and locations; perform cutting operation. 19. Identify different methods of attaching non-structural components (squeeze type

5 resistant spot welds (STRSW), riveting, non-structural adhesive, silicon bronze, etc.) F. Plastics and Adhesives 1. Identify the types of plastics; determine reparability. 2. Clean and prepare the surface of plastic parts; identify the types of plastic repair procedures. 3. Repair rigid, semi-rigid, or flexible plastic panels. 4. Remove or repair damaged areas from rigid exterior composite panels. 5. Replace bonded rigid exterior composite body panels; straighten or align panel supports. Course Outline: I. Auto Body Materials and Fasteners A. Refinishing materials B. Fasteners II. Welding Equipment and its Use A. MIG Welding B. Flux-Core welding C. TIG welding D. Other welding techniques-resistance spot, stud spot, mold rivet, Oxyacetylene E. Brazing and soldering III. Minor Body Repairs A. Applying fillers B. Repairing nicks, dings and rust IV. Plastics A. Types B. Repair V. Adhesives A. Chemical adhesives B. Plastic welding C. Repairing vinyl Course Structure: Students will be expected to participate in class/group discussions and activities. Students will also be required to develop and maintain a notebook of course content. Outside assignments are an integral component of this course. The instruc tor reserves the right to change, shorten or lengthen, delete or insert to any task found necessary for the benefit of each student. This syllabus is a guideline and the instructor reserves the right to make any needed and necessary changes Technology/Media Component: Calculators (not supplied by the program) may be used to work mathematical problems encountered during the course. A combination of lecture, audio-visual materials, and class assignments will be utilized Service-Learning: Service-Learning is a teaching methodology that connects learning to service. Both the learning and the service are strengthened by the connection. Students are taught course specific skills (PREPARATION), solve real community issues using classroom learning(action/service), return to the classroom setting and REFLECT upon the application of course skills and are given the opportunity to CELEBRATE their victories. This is known as the PARC Model Course Requirements and Evaluation:

6 EVALUATION /GRADING POLICY: The Final grade for the course will be determined by averaging the scores you have earned from class assignments, written exams, performance exams, and other miscellaneous assignments. Note: Some class assignments may not be included in the grade calculations. The Grading Scale will be as follows:100%-90%=a; 89%-80%=B; 79%-70%=C; 69%- 60%=D; 59%and below=e Grades will be calculated as follows: Unit exams and Quizzes: 10%Participationand Quality of Work:90% Grading Policy: The Final grade for the course will be determined by averaging the scores you have earned from class assignments, written exams, performance exams, participation, and other miscellaneous assignments. Note: Some class assignments may not be included in the grade calculations. The Grading Scale will be as follows: 100%-90%=A;89%-80%=B;79%-70%=C; 69%-60%=D;59%andbelow=E All work is graded and calculated according to percentages shown above Pop Quizzes will usually be given at the beginning of class and there will be 10 minutes allowed for each one. These will be unannounced and cannot be made up for a grade. You must earn at least a 70% in this class for it to count toward a certificate or diploma Attendance Policy: Regular attendance and punctuality are expected of all students. Work missed because of absence(s) for any reason shall be made up satisfactorily to the instructor. Makeup work not turned in by the time designated by the instructor shall receive a grade of 0. It is the student s responsibility to contact the instructor to arrange for makeup work. Any assignment that is turned in late will receive an automatic 15% deduction. If you are tardy for a class, please come in quietly as to not disturb the rest of the class. Quizzes relating to both the lab and safety cannot be made up. Missed Exam Policy: Make-up work is the responsibility of the student. If the student misses an exam or assignment, it is his/her responsibility to meet with the instructor to determine a make-up date. Quizzes cannot be made up, all missed assignments or exams may not be considered if not completed within seven days of the exam or assignment date. A 15% deduction will applied to all late work Late Assignment Policy: All missed assignments or exams may not be considered if not completed within seven days of the exam or assignment date. A 15% deduction will apply to all late work. Online quizzes may not be made up. Withdrawal Policy: Students may withdraw from this course at any time during the semester/term, up until the last day to withdraw from class (decided by systems office). Students who choose to withdraw should request drop form signed by the instructor and advisor and processed through the business office. If this is not done, the student will remain enrolled in this class and will be responsible for all assignments and tasks. Additional information can be found at the following site:

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