ITI Mechanic Auto Body Painting (AITT Theory) study plan
ITI Mechanic Auto Body Painting (AITT Theory) · Give each week a clear focus.
8 weeks · About 7 hours per week
Trade Safety, Tools, and Workshop Practice & Health, Environment, and Waste Management
List the PPE items required for each task in a refinish shop (mixing, spraying, sanding, welding, gun cleaning) and state the standard each item protects against
Explain how a supplied-air respirator differs from an air-purifying respirator, and identify which tasks in a paint shop demand supplied air
Describe the correct storage, handling, and segregation rules for solvents, catalysts, and waste streams in a body shop
Identify the main hazards of isocyanate-containing products and the exposure controls that reduce risk
Label a hand-drawn shop-floor sketch showing ventilation direction, mixing area, spray booth, and waste collection points
Your checkpoint
A two-page safety and environmental reference sheet covering PPE by task, respirator selection, and waste segregation, self-quizzed to 90% accuracy
Surface Preparation and Substrate Assessment
Identify substrate types (steel, aluminium, galvanized, plastic, OEM e-coat, cured and uncured finishes) and state the prep method for each
Demonstrate the sequence of washing, degreasing, and sanding a panel and explain why order matters
Distinguish between wax-and-grease remover, plastic adhesion promoter, and etch primer, and select the right one for three given scenarios
Explain how to test for and treat surface contamination that causes fisheyes or poor adhesion
Describe grit selection and sanding scratch depth relative to the next coating applied
Your checkpoint
A substrate-to-prep-method decision table covering at least eight substrate or condition cases, plus a written prep sequence for one full panel
Body Filling, Panel Repair, and Dent Removal
Describe the steps for mixing and applying body filler, including surface prep, filler-to-hardener ratio, and working time
Explain how to shape, sand, and finish filler with a sanding block and guide coat, and how to check for low and high spots
Outline methods for dent removal including hammer-and-dolly, stud welding, and glue pulling, and state when each is appropriate
Explain how to repair a plastic bumper including identification, adhesion promoter, and flexibility additive use
Identify common filler and panel-repair failures and their corrections
Your checkpoint
A step-by-step filler and dent-repair procedure for one panel, written from memory and checked against a verified reference, with a list of five failure modes and their causes
Paint Materials, Mixing, and Color Matching & Primers, Sealers, and Undercoats
Explain mixing ratios by volume versus by weight and calculate batch sizes for three given ratios
Describe pot life, induction time, and the effect of temperature on both
Distinguish primer, sealer, primer-surfacer, and etch primer by purpose and application
Explain the role of a sealer over body filler and over sanded-through edges
Describe how color is matched using variant chips, spray-out cards, and tinting adjustments
Your checkpoint
A mixing and undercoat worksheet with five worked ratio calculations, pot-life notes, and a primer-versus-sealer selection guide, self-marked to at least 85%
Spray Application Techniques and Equipment
Identify the parts and adjustments of a gravity-feed spray gun and explain what each control changes
Explain fluid tip size selection for primer, basecoat, and clearcoat, and the effect of each on finish
Describe correct gun distance, angle, overlap, speed, and triggering for a uniform coat
Diagnose common spray faults (orange peel, runs, dry spray, mottling) and state the adjustment that corrects each
Outline spray gun cleaning and maintenance steps that preserve pattern quality
Your checkpoint
A spray-fault troubleshooting chart with at least eight faults, their likely causes, and corrective adjustments, plus a gun-setup checklist
Topcoats, Clearcoats, and Finishing Defects
Explain the purpose and application of basecoat, midcoat, and clearcoat, and how coats build to full hiding
Describe blending techniques for a panel-to-panel repair and the role of a blend prep or blend solvent
Identify finishing defects (dust nibs, solvent pop, runs, die-back, overspray, sand scratch swelling) and their causes and corrections
Explain the steps to cut, polish, and buff a cured finish without burning through the clearcoat
Describe drying, curing, and bake-cycle considerations and their effect on finish quality
Your checkpoint
A finishing-defect and correction matrix of at least ten defects, plus a written blend procedure for one adjacent panel
Measuring, Estimating, and Customer Handover & Trade Safety, Tools, and Workshop Practice
Read a repair order and identify the operations, materials, and labor categories involved
Explain how to measure and estimate refinish time using panel counts and blend factors
Describe how to document a repair with photos, material records, and a written handover note
Outline a customer handover checklist covering finish inspection, care instructions, and warranty explanation
Describe tool and equipment inspection and maintenance routines that support safe, accurate work
Your checkpoint
A complete sample estimate and customer handover package for one multi-panel repair, including labor breakdown, material list, and handover checklist
Surface Preparation and Substrate Assessment & Paint Materials, Mixing, and Color Matching & Spray Application Techniques and Equipment & Body Filling, Panel Repair, and Dent Removal & Primers, Sealers, and Undercoats & Topcoats, Clearcoats, and Finishing Defects
Review weak areas from prior weeks and re-test each at 90% or better
Work through at least 60 practice questions across all domains and log every error with its cause
Re-derive key ratios, mix calculations, and fault-to-cause mappings from memory
Explain one complete repair job end to end, from assessment through prep, filler, undercoat, topcoat, and handover
Confirm readiness by reviewing the study plan and identifying any remaining gaps
Your checkpoint
A full practice exam scored at 85% or higher, with a written error log showing corrected reasoning for every missed question
Milestones
Week 2: Can state the correct prep method and coating sequence for any of eight substrate cases without notes
Week 4: Scores at least 85% on a self-made mixing, ratio, and undercoat quiz and correctly selects primer versus sealer in five scenarios
Week 6: Can diagnose at least eight spray and finishing defects from a written description and name the corrective adjustment
Week 8: Scores at least 85% on a 60-question mixed practice exam and can explain one full repair job end to end