ITI Mechanic Auto Body Repair (AITT Theory) study plan

Map shop hazards (fume, hot work, compressed gas, high-voltage, manual handling) to the specific PPE, screening and ventilation control each one requires, and state the correct filter cartridge and eye-shade number per task.

Sequence a pre-start inspection on GMAW, resistance spot and oxy-acetylene equipment: flashback arrestors, regulator pressures, hose and cable insulation, work-lead grounding, and fire watch placement.

Differentiate GMAW, TIG, squeeze-type resistance spot and oxy-acetylene in terms of where each is permitted on mild steel, high-strength steel, UHSS and aluminium body panels, and name the applications where heat is prohibited.

Record welding parameters (wire-feed speed, voltage, gas flow, current, travel speed) for 0.8 mm and 1.2 mm sheet and explain how heat input and stitch sequencing drive distortion and panel warpage.

Explain brazing, soldering and structural adhesive bonding as joining alternatives: joint preparation, filler selection and where each is preferred over fusion welding.

Select and justify measuring and marking tools (steel rule, dividers, trammel points, profile gauge, vernier caliper, depth gauge) for a given panel task, and describe how to zero-check and read each to its stated precision.

Identify panel steel types by marking and behaviour (mild steel, HSS, UHSS, aluminium, galvanized) and state the cutting, forming and heat constraints each imposes.

Lay out a patch repair on a rusted rocker or wheel-arch section: mark cut lines, set overlap or flanged butt allowance, and define bend lines and hem allowance.

Explain stretch and shrink in hand forming: hammer and form-block shaping, shrinking with a shrinking hammer or torch, and the use of an English wheel for crown.

Apply repair-versus-replace criteria (panel gap, contour, access, structural classification, cost) to three described damage cases and defend each decision.

Classify body construction types (body-on-frame, unitized, space frame, unitized with bolt-on subframes) and mark which members are structural and energy-managing versus cosmetic.

Explain crumple zones, reinforced pillars, kick-up sections and how sectioning rules and weld locations are determined for a structural member.

Read underbody and centreline measurement data against a datum sheet, convert the readings into a diagnosis, and state the tolerance band that sends a vehicle to the frame rack.

Sequence a structural pull: anchoring and blocking, pull direction and angle, measuring while pulling, watching for secondary damage, and deciding when heat is permitted.

Relate steering and suspension geometry readings (camber, caster, SAI, included angle, thrust line) to structural misalignment and describe what each offset implies.

Distinguish elastic from plastic deformation on a described dent and locate the stretched crown versus the shrunk or oil-canned zone before choosing a technique.

Match hammer and dolly pairs to panel crown and apply on-dolly versus off-dolly striking correctly, explaining what each does to the metal.

Order a full dent repair sequence: stress relief, pick or stud pull, glue pulling where heat is barred, shrinking, filling and contour finishing.

State when heat shrinking, stud welding or glue pulling is acceptable on high-strength and UHSS panels and when it must be avoided entirely.

Judge body filler work: mixing ratio, maximum thickness, grit progression from shaping to finish, pinhole and edge-feather control, and contour matching to adjacent panels.

Sequence a full refinish from bare metal to polish: metal treatment, etch or epoxy primer, filler and primer-surfacer, sealer, base coat, clear coat, cut and polish, with recoat windows noted.

Match paint systems (2K acrylic urethane, waterborne base, single-stage, low-VOC) to substrate and primer compatibility and state where each is inappropriate.

Set up a spray gun: fluid tip and needle size, air cap choice, cap pressure, fan pattern, fluid flow and a test spray on card before the panel.

Diagnose finish defects including orange peel, solvent pop, runs and sags, blushing, fish-eye, pinholing and die-back, giving cause and correction for each.

Explain colour matching and blending techniques, including blend-within-panel, edge-to-edge, hiding and the effect of substrate and flash time on match.

Identify bumper, trim and underbody plastics by ISO/SAE code and confirm by burn or float test, then state whether the part is repairable, refinished or replaced.

Compare thermoplastic repair routes: hot-air welding with compatible rod, nitrogen welding for PP and EPDM, two-part structural adhesive with backing reinforcement, and stapling, giving the strength trade-off of each.

Lay out a fibreglass or composite repair: taper and bevel, resin-to-hardener ratio, mat versus woven cloth selection, layer sequence, cure and finish sanding.

Diagnose body electrical faults with a digital multimeter: voltage-drop testing, parasitic draw measurement, ground integrity and continuity, and trace a circuit from a wiring diagram using wire colours and connector numbers.

Explain body accessories and their service precautions: power windows, central locking, mirrors, lighting and SRS component handling before and during body repair.

Sequence trim removal and refit without breaking clips or fasteners across door cards, headliner, seats, carpet and pillar trims, naming the fastener and clip types and the correct removal tool for each.

Compare bonded glass installation methods (urethane versus butyl), and state the preparation, primer, bead dimension and safe-cure time required for a windscreen replacement.

Fit and adjust weatherstrips, door glass run channels and belt mouldings, and diagnose water leaks and wind noise by alignment, seal compression and drain path.

Build a repair estimate from a damage description: parts, body labour, refinish labour, paint and materials, sublet, betterment and tax, with the reasoning for each line.

Prepare job documentation and customer contact: repair order, authorization, supplement and photo record, and a plain-language explanation of the repair to the customer.

Sit timed mock exams weighted to the heavy domains until each of Domains 3, 4, 5, 6 and 8 scores at least 85 percent.

Compress the highest-yield facts into a one-page card: weld parameters, measurement tolerances, paint mixing ratios, primer recoat windows and frame pull limits.

Re-derive every missed item from the weekly error logs and state the underlying principle rather than memorizing the answer.

Work the light domains (1, 2, 7, 9, 10, 11) in short retrieval sets to hold recall without spending a full session on them.