I-CAR Non-Structural study plan

Map each major vehicle construction category (body-on-frame, unibody, space frame, aluminum-intensive, mixed-material) to its collision energy-management path and write a one-page comparison table from memory.

Identify by name and function at least ten substrate and strength-designation terms (mild steel, high-strength steel, ultra-high-strength steel, boron, 5xxx vs 6xxx aluminum, carbon fiber, magnesium, plastic families) and state one repair restriction for each.

Explain in writing why heat, sectioning location, and fastener choice differ between mild steel and advanced high-strength steel, citing the metallurgical reason rather than a rule number.

Locate and summarize the OEM collision repair information portal structure for two different manufacturers, noting where construction, material, and sectioning documents live.

List the vehicle systems that must be scanned or inspected after a collision (airbags, seat belts, occupant detection, cameras, radar, battery) and note which domain each belongs to in this exam outline.

Sequence the removal of a front fender, hood, and front door on a unibody vehicle, listing the fasteners, clips, wiring, and adjustment points in order.

Describe the gap-and-flush measurement method for aligning a hood and a door, including which fasteners to loosen, in what order, and how to verify with a gauge.

Differentiate bolted-on, removable, and welded panels and state which attachment method applies to each panel you listed in week 1.

Diagnose three common fitment complaints (wind noise, uneven gap, water leak) by tracing each to an alignment or sealing cause.

Explain how to protect adjacent panels, glass, and sensors during panel removal and where to store removed panels to avoid damage.

Classify dents by access, depth, and substrate, and match each class to a repair approach (push-to-paint, glue pull, stud weld, panel replacement) with a justification.

Demonstrate the hammer-and-dolly and glue-pull sequences on a practice panel and record the steps that prevent stretched metal and over-thinning.

Explain when filler is and is not acceptable, including substrate limits, maximum thickness guidance, and the reason filler over a crease or structural area is prohibited.

Describe surface preparation, mixing, application, and finishing steps for body filler and glaze, and list the defects (pinholes, ridges, solvent pop) with their causes.

Outline corrosion protection layers and seam-sealing steps after a panel repair, naming where sealant, cavity wax, and primer must be reapplied.

Compare squeeze-type resistance spot welding, MIG brazing, and structural adhesive bonding on heat input, substrate suitability, and typical non-structural applications.

Describe weld-bonding and list the steps, clamp times, and adhesive cure considerations that differ from welding alone.

Explain how to plan a sectioning cut on a non-structural panel: cut location selection, backing plate or insert use, and corrosion protection of the joint.

Identify the destructive and non-destructive tests used to verify a weld or bond (peel test, chisel test, visual acceptance criteria) and state the acceptance standard for each.

List the personal protective equipment, fume extraction, and fire-watch requirements for welding and adhesive work in a collision shop.

Execute a full repair workflow on a practice panel: damage assessment, repair or replace decision, panel work, filler, primer, sealant, and corrosion protection.

Justify a repair-versus-replace decision for three damage scenarios using substrate, access, cost, and OEM restriction as criteria.

Apply seam sealer and cavity wax to a simulated repair and inspect for missed areas using a written corrosion-protection checklist.

Self-inspect a finished panel against a gap, flush, finish, and corrosion criteria list and document every deviation.

Describe removal and installation of a bonded windshield and a bolted quarter glass, including urethane bead placement, primer use, and safe-drive-away time.

Explain trim clip types, retention strategies, and how to remove interior panels without breaking clips or disturbing airbag modules and side-curtain routing.

Classify plastics by identification symbol and match each family to the appropriate repair method (hot air weld, plastic adhesive, two-part repair) or replacement.

Outline bumper cover and fascia repair: substrate identification, reinforcement of tears, refinish prep, and when replacement is required.

Identify which bumper and trim components conceal sensors, cameras, or antennas and state the handling precaution for each.

List the ADAS features commonly fitted to late-model vehicles (forward collision warning, automatic emergency braking, lane departure, blind spot, adaptive cruise, rear cross traffic, surround view) and name the sensor type behind each.

Explain the difference between static and dynamic calibration, and state what conditions (ride height, tire size, fuel level, cargo, target placement) can invalidate a calibration.

Describe the pre-scan and post-scan requirement, what a scan tool reveals, and why a clear dash lamp is not proof that systems are functional.

Trace how a bumper cover, windshield, or ride-height change can shift sensor aim and trigger a recalibration requirement.

Outline the shop workflow for documenting a calibration: who performs it, what is recorded, and how the record is attached to the repair file.

Assemble a repair file for one simulated job containing the OEM procedure reference, pre- and post-scan records, materials used, and the final quality inspection sign-off.

Explain why following OEM procedures is a documentation and liability issue, and describe what to do when a procedure cannot be found.

Audit your own week 1-7 deliverables against the exam outline and list the three weakest topics with a corrective study action for each.

Complete a timed mixed-topic review of at least 60 self-written recall questions spanning all ten domains and score it.

Write a one-page summary of the repair process from damage assessment to delivery, naming the quality gate at each stage.