Vehicle Body
This domain covers body construction, panels, frames, crash structures, panel alignment, dent repair, welding, sealers and corrosion protection. The exam tests how body repairs restore appearance, fit and safety.
Core rules
Modern bodies use high-strength and ultra-high-strength steels, aluminium and composites. These materials have repair limits: some must not be heated, and some must be replaced rather than straightened. Panel gaps and flushness are measured against the opposite side or manufacturer dimensions. Structural sections must be cut at approved locations and joined with the specified welding or adhesive method. Cavity wax, seam sealer and anti-corrosion coatings must be restored after repair. A body pull should be measured with a jig or electronic measuring system, not by eye.
Worked example
A bonnet-to-fender gap is specified as 4.5 ± 0.5 mm. The measured gap is 5.2 mm, which is 0.2 mm outside the upper limit. Before adjusting the hinge, check that the fender is correctly located and that the bonnet is not twisted. If the fender is correct, loosen the hinge bolts, reposition the bonnet to 4.5 mm, check flushness with the fender and headlamp, then tighten to the specified torque. Forcing the panel can crack paint and preload the hinges.
Traps
Heating high-strength steel to shrink a dent; sectioning a rail at a non-approved point; skipping cavity wax after welding; and aligning a panel to a damaged adjacent panel. Always check the opposite side of the vehicle for the original gap.