I-CAR Structural study plan

Build a one-page glossary that defines 30 collision-repair terms (unibody, body-over-frame, crush zone, setback, mash seam, tailor-welded blank) in your own words and cite a source line for each

Diagram the force path through a unitized front end for a 40% frontal offset impact, labeling crush zone, transition zone, and occupant compartment boundaries

List the 12 inspection checkpoints you would complete on a front-rail collision before any measurement begins, and state what evidence at each point tells you the damage extends further

Classify 10 given damage descriptions as direct, indirect, or induced damage and justify each classification in one sentence

Identify the three vehicle reference systems (datum, centerline, symmetric) and explain in writing which one you would trust first on a unitized front-end hit and why

Practice setting up a three-dimensional measuring system on a training vehicle or mock fixture and record 10 control-point readings with tolerance values

Calculate allowable deviation for five control points using the OEM body repair manual specification, and flag which readings exceed tolerance

Write the sequence you would follow to fixture a vehicle before pulling, listing clamp locations and the reason each clamp is placed there

Explain the difference between a single-pull and a multi-pull correction and state the condition that forces you to switch strategies

Describe three methods of anchoring a vehicle for pulling and the structural reason each anchor point is chosen

Draft a pull plan for a swayed front rail that includes anchor points, pull direction, expected hold time, and the measuring checkpoints between pulls

List five signs of overpulling or stress-induced damage and the corrective action for each

Describe the squeeze-type resistance spot welding (STRSW) circuit and name the four primary variables that control weld nugget formation

State the correct procedure for preparing mating surfaces, applying weld-through primer, and clamping flanges before an STRSW weld

Explain how to perform a destructive test weld (peel or chisel test) and what nugget diameter and failure mode you are looking for

Identify five common STRSW defects (undersized nugget, expulsion, surface indentation, shunting, no fusion) and their likely causes

Compare MIG and MAG transfer modes and state which shielding gas mix suits each on thin-gauge and high-strength substrates

Set up a MIG welder for a butt joint with backing on 1.0 mm steel and record voltage, wire feed speed, gas flow, and travel angle used

Describe the correct preparation for a butt joint with backing, a lap joint, and an open butt joint, including gap and bevel requirements

Explain why sectioning joints must be placed in low-stress zones and list three locations on a unitized vehicle where a sectioning joint is generally acceptable

Outline the decision sequence for choosing between STRSW, MIG plug weld, rivet bonding, and adhesive bonding for a given panel attachment, naming the OEM-dictated constraint at each branch

List the surface-preparation steps for adhesive bonding on bare steel, galvanized steel, and aluminum, and note where they diverge

Describe the correct rivet-bonding sequence (adhesive application, rivet placement, clamp time, cure time) and the consequence of riveting before the adhesive is fully seated

Identify the removal precautions for a panel attached with structural adhesive, including heat limits and what heat does to surrounding high-strength steel

Map the corrosion-protection layers on a unitized body (e-coat, seam sealer, cavity wax, underbody coating) and state where each is applied and what it protects

Write the restoration steps after a welded panel replacement, from bare-metal prep through cavity wax application, in correct order

Explain how heat input affects advanced high-strength steel (AHSS) and state the temperature and time limits you would observe when applying heat near a boron or martensitic component

Describe mixed-material joining concerns when aluminum meets steel, including galvanic corrosion and isolation methods

Complete a timed 60-question mixed practice set weighted to the domain percentages and score it against an answer key

Re-teach your three weakest topics from the practice set in writing, each in under 150 words, without looking at notes

Re-derive the measurement tolerance check and the STRSW destructive-test criteria from memory and compare against your week 2 and week 4 deliverables

Build a one-page exam-day checklist of the procedures you must not skip (fixture before pull, test weld before production weld, cavity wax after welding)