ASE B4 Structural Analysis & Damage Repair study plan

Name and locate the major unibody and body-over-frame structural members (rails, aprons, strut towers, crossmembers, rockers, pillars, hinge and latch pillars) from memory without notes

Classify ten vehicle designs as unibody, body-over-frame, or space-frame, and state which members carry primary load in each

Write the inspection sequence from outermost bolt-on panels inward to the rails, listing what to look for at each step

Distinguish between collision energy management features (crush zones, reinforcements, ultra-high-strength steel zones) and where heat or sectioning is restricted

Build a 30-item pre-repair inspection checklist ordered by inspection sequence

Identify the five classic collision damage patterns (sway, mash, diamond, twist, side-sway combination) on a practice or salvage vehicle and label each with its location

Check gap and flush on at least four panel pairs and record deviation in millimeters

Trace a suspected rail kink from a bolt-on panel misalignment back to its structural origin using the inspection sequence from week 1

Record findings on a written damage report using consistent terminology (kink, buckle, crush, deformation, misalignment)

Take at least 20 reference measurements with a tape, tram gauge, or centerline gauge and record each against a stated reference point

Verify body squareness using the 3-4-5 triangulation method and document the calculated result

Convert raw measurements into deviation-from-spec values and rank findings by severity

Determine whether a measured deviation indicates a bolt-on adjustment issue, a repairable pull, or a component replacement

Write the reasoning for each severity ranking so a reviewer could follow the decision

Set up a GMAW machine for the correct wire, gas, and polarity on three sheet-steel thicknesses and record the settings used

Run continuous beads, stitch welds, and plug welds on 22-gauge, 18-gauge, and 16-gauge coupons without burn-through

Perform a destructive peel or bend test on each coupon and record pass or fail against a stated acceptance criterion

Apply heat-input control practices (skip welding, backing, heat sinks) and explain how each limits distortion

Identify when squeeze-type resistance spot welding is required instead of plug welding

Write a step-by-step pull sequence for a simulated front-rail sway, including anchor points, pull direction, and hold points

Select appropriate pulling and anchoring points for three different damage scenarios and justify each choice

State the heat limits and prohibited heating zones for high-strength and ultra-high-strength steel and explain why the limit exists

Plan a multi-pull sequence with stress-relief and re-measurement checkpoints between pulls

Identify three errors that would turn a repairable deformation into a replacement job

Apply repair-versus-replace criteria to ten written damage scenarios and record the deciding factor for each

Plan a sectioning joint: choose the cut location, describe the backing and joint type, and state the corrosion protection steps

Outline the removal and installation sequence for a bolt-on structural or semi-structural panel, including alignment checks before and after

Describe corrosion protection and seam sealing steps required after any welded or sectioned repair

Explain how a mis-sequenced installation creates secondary misalignment

Write a full replacement procedure for one welded structural panel, from initial measurement to final inspection

Specify the weld types, weld spacing, and sequence for the installation, including plug and stitch locations

Sequence the clamping and alignment steps so dimensions are verified before final welding

List the post-installation checks (dimensional, gap and flush, corrosion protection, seam sealer, weld appearance) in order

Identify at least four failure points in a replacement job and the check that catches each

Complete a timed 60-question practice exam covering all five domains under exam conditions

Categorize every missed question by domain and by error type (knowledge gap, misread, measurement error, procedure sequence)

Re-drill the two weakest domains with targeted practice until accuracy reaches 85 percent

Recite the inspection sequence, repair-versus-replace criteria, and weld acceptance criteria from memory without notes

Build a one-page pre-exam reference sheet of formulas, limits, and sequences to review in the final 48 hours