I-CAR ProLevel Refinish study plan
I-CAR ProLevel Refinish · Give each week a clear focus.
8 weeks · About 7 hours per week
Surface Preparation and Substrate Identification & Application Techniques and Coating Defect Prevention
Classify each substrate type (steel, aluminum, galvanized, plastic, SMC, OEM e-coat, prior refinish) and state the correct preparation sequence for each without notes
Map the full prep workflow from wash through final sand grit, listing the grit progression and why each step exists
Identify the three contamination classes (silicone/oil, moisture, dust/particulate) and name the removal method and failure symptom for each
Build a one-page decision tree for plastic part prep covering adhesion promoter versus no promoter by plastic family
Explain how surface prep errors surface later as defects such as peeling, solvent pop, and fish eyes
Your checkpoint
A written substrate-to-prep matrix covering at least 8 substrate types, self-scored at 90% or better against a checklist you build from the domain objectives
Application Techniques and Coating Defect Prevention & Surface Preparation and Substrate Identification
Diagram each coating layer (primer, sealer, base, mid-coat, clear) and state the film-build target and dry-film tolerance for each
List the flash-time and recoat-window rules for the products in your shop and describe what happens when each is violated
Diagnose at least 10 named defects (solvent pop, runs, sags, mottling, die-back, orange peel, blisters, lifting, hazing, pinholing) by cause, prevention, and repair
Sequence a panel repair plan that avoids trapping solvents and respects recoat windows across three coats
Practice spray-gun distance, angle, and overlap on a test panel and record the pattern width and overlap percentage that produced a uniform film
Your checkpoint
A defect troubleshooting table with 10+ defects, each with cause, prevention, and repair, plus a photographed test panel showing an even, defect-free clear coat
Color Matching, Mixing, and Tinting & Surface Preparation and Substrate Identification
Explain the three dimensions of color (hue, value, chroma) and demonstrate reading them on a color chip under controlled lighting
Perform a variant check procedure: locate the OEM color code, confirm the variant, and spray an outdoor spray-out card for comparison
Mix base coat to a stated ratio using a mixing bank or scale and verify the ratio math for a partial batch
Tint a mismatched batch toward the spray-out using the correct tint direction and record each tint addition
Identify the effect pigments (metallic, pearl, mica, tri-coat) and describe the spray technique each one demands
Your checkpoint
Three spray-out cards for one OEM color matched to a variant within an acceptable visual and spectrophotometer reading, with a tint log documenting each addition
Refinish Safety, Health, and Environmental Compliance & Refinish Materials, Product Selection, and Documentation
Assemble the PPE required for isocyanate-containing clears, solvents, and sanding dust and state the cartridge or supplied-air requirement for each task
Explain the difference between a cartridge respirator and supplied-air and identify which tasks require supplied air
Outline the VOC and hazardous-waste handling rules that govern gun cleaning, solvent storage, and waste stream segregation
Read a product data sheet and safety data sheet and extract mix ratio, pot life, VOC content, and required PPE
Describe the documentation trail required for a repair: color code, product batch, mix ratio, and cure conditions
Your checkpoint
A completed mock job file for one repair containing the SDS/PDS extracts, PPE selection, waste disposal plan, and a written record of color code, batch numbers, and mix ratios
Spray Equipment Setup, Operation, and Maintenance & Application Techniques and Coating Defect Prevention
Disassemble, clean, and reassemble a gravity-feed HVLP gun and identify each component and its failure mode
Set fluid tip, air cap, and inlet pressure for a primer, base, and clear application and record the settings
Diagnose spray pattern faults (split, crescent, heavy center, spitting) from the pattern shape and state the fix
Demonstrate proper gun cleaning and storage so the next session starts with a clean, correctly assembled gun
Apply a full wet coat and a tack coat on a test panel and compare film build, texture, and coverage
Your checkpoint
A gun setup and maintenance log for three products with recorded pressures, tip sizes, pattern test results, and a maintenance schedule
Color Matching, Mixing, and Tinting & Application Techniques and Coating Defect Prevention
Blend a base coat into an adjacent panel so the transition is invisible under both shop and daylight lighting
Perform a panel repair from prep through clear on a scrap panel and self-evaluate against a defect checklist
Adjust for temperature and humidity by selecting the correct reducer and hardener speed and justify the choice
Correct a mottled or blotchy metallic repair and document the technique used to recover it
Compare a repair against a control panel under color-corrected light and record any remaining mismatch
Your checkpoint
One completed panel repair with before/after photos, a defect self-evaluation sheet, and a written justification of reducer and hardener selection
Refinish Materials, Product Selection, and Documentation & Refinish Safety, Health, and Environmental Compliance
Select the correct primer, sealer, base, and clear system for three different substrate and job scenarios and justify each pick
Verify a product is compatible with the substrate and the existing finish before application and state what happens when it is not
Complete a full documentation packet for a repair including product selection rationale, VOC compliance, and waste handling
Explain warranty and OEM approval considerations that affect which products may be used on a given vehicle
Audit your own shop practices against the safety and environmental rules you studied and list any gaps
Your checkpoint
A product selection and documentation packet for three scenarios, each with product choice, compatibility check, VOC compliance note, and safety plan
Surface Preparation and Substrate Identification & Color Matching, Mixing, and Tinting & Spray Equipment Setup, Operation, and Maintenance & Application Techniques and Coating Defect Prevention & Refinish Materials, Product Selection, and Documentation & Refinish Safety, Health, and Environmental Compliance
Complete a timed 60-question practice set across all six domains and score 85% or better
Review every missed question and write the underlying rule or procedure it tested
Re-run a full repair from prep through clear under time pressure and hit the defect-free standard
Recite the safety, PPE, and waste-handling rules from memory without notes
Build a one-page quick-reference sheet covering substrate prep, mix ratios, gun settings, and defect causes
Your checkpoint
A scored practice set of 60 questions at 85% or better plus a one-page final reference sheet and a written list of remaining weak areas with a remediation plan
Milestones
Week 2: Score 80% or better on a self-made 25-question quiz covering substrate identification, prep sequence, and defect causes; the defect table must cover 10 or more defects
Week 4: Explain aloud, without notes, the PPE and supplied-air requirements for isocyanate clear and the waste-handling rules for gun cleaning; the mock job file must be complete on all required documentation fields
Week 6: Complete a panel repair with no more than one minor defect and an invisible blend under daylight inspection; reducer and hardener choices must be justified in writing
Week 8: Score 85% or better on a timed 60-question mixed-domain practice set and complete a full timed repair that meets the defect-free standard