Damage Repair and Alignment
Damage Repair and Alignment tests damage assessment, measuring, pulling, anchoring, sectioning and replacement. You must decide whether a part can be repaired, realigned or replaced, and prove alignment with measurements.
Core rules
- Inspect the whole vehicle: direct damage, indirect damage, suspension mounting points, gaps and underbody control points.
- Measure before pulling. Use a tram gauge, centre-line gauge or dedicated measuring system against datum dimensions.
- Anchor the vehicle at the specified points before applying pulls; pull in the direction opposite to the impact.
- Use controlled heat only where permitted; high-strength steel may lose strength if overheated.
- Section only at approved locations; restore reinforcement, weld quality, seam sealer and corrosion protection.
- After structural repair, check panel gaps, wheel alignment and function of closures and systems.
Worked example
A front corner impact leaves the bumper and wing damaged and the door gap tight. Measuring control points shows the left apron is 15 mm rearward. The repairer anchors the vehicle, pulls the apron forward in stages, releases tension and re-measures after each pull. The wing is replaced only after the structure is back to datum. Reasoning: replacing the wing first would hide the structural error and leave poor gaps.
Traps
Do not pull without anchoring. Do not heat a high-strength rail to cherry red. Do not measure to a damaged panel. Do not repair cosmetic damage over a bent suspension mount.