Car Body Construction

Course Overview

The course is designed to follow on from the continuation course putting into practice the principles established to make or restore complex sheet metal panels and structures.

Students are encouraged to bring along their own project to work on under expert supervision.

Course Aims

To enable students to produce and restore complex panels and structures.

Subjects covered

Theory

Body construction - Exploring the various methods of construction used in vehicle bodies

Body Design - Discussing aesthetics and mechanics of car body design

Body Restoration - Discussing principles and practice of vehicle restoration

Corrosion prevention - Understanding and minimising the effects of corrosion on materials

Practical

Making panels - Forming complex panels and structures

Repairing panels - Analysing corroded and damaged parts. Deciding how much to replace and where best to position welded joints. Removing rusted areas.

Welding - Practicing the various forms of welding used on panels; MIG, TIG, Oxy Acetylene and resistance spot.

Flanging - Forming flanges around tooling using advanced techniques.

Shaping - Forming and smoothing complex double curvature panels to accurately fit jig.

Butt-Welding - Using TIG welder to join thin sheet steel and aluminium alloys without filler rod enabling joint to be planished to a smooth finish.

Finishing - Lead loading, use of abrasives, power tools and hand finishing.