Collision Repair Workbook: Panel Work, Welding, and Frame Straightening

Collision repair technicians develop competence through structured, sequential practice — starting with small dent repair and progressing to structural sectioning and frame work. Skipping this progression produces technicians who can copy what they see an experienced tech do but cannot reason through an unfamiliar damage pattern. This workbook provides the sequential framework. By the end of this course you will be able to execute a planned dent repair sequence on a non-structural panel, set up and execute a MIG weld to the specifications required for panel replacement, read a vehicle measuring report and identify out-of-tolerance dimensions, and describe the straightening sequence for a common front-impact damage pattern. What you will learn: - Dent repair planning: damage mapping, access assessment, and tool selection for hammer-and-dolly versus stud-pull approaches - Panel straightening sequence: working from the outside edges of damage toward the center to avoid stress concentration - Sectioning decisions: where panels may be sectioned versus full replacement — manufacturer position statement research - MIG welding setup for collision repair: wire selection, shielding gas, voltage and wire-feed settings for different metal thicknesses - Squeeze-type resistance spot welding (STRSW): the OEM-preferred method for flange welds and how to verify weld quality - Aluminum repair basics: dedicated tools, heat management, and cross-contamination prevention with steel repair areas - Frame measuring with a computerized system: datum targets, tolerance ranges, and interpreting a pull sequence from measurement data - Pull planning: anchor placement, pull direction, and sequence for restoring structural dimensions Each module pairs technique description with a worked example repair scenario, then presents a decision checklist for the procedure type. Planning worksheets help structure the repair assessment before work begins. Written for collision repair students and entry-level technicians in a shop environment who want a more structured approach to skill development than observation alone provides. Suitable for anyone new to structural panel and welding work. This course is educational; structural repair work must be performed under qualified supervision and in compliance with vehicle manufacturer repair procedures, as improper structural repair creates serious safety risks.