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«TEACHER’S GUIDE S H O P WA R E ® INTRODUCTION This Teacher’s Guide provides information to help you get the most out of Surface Preparation and ...»

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S H O P WA R E ®


This Teacher’s Guide provides information to help you get the most out of Surface

Preparation and Refinishing. The contents in this guide will enable you to prepare your students before using the program and present follow-up activities to reinforce the program’s key learning points.

A glimmering coat of paint is the finishing touch to an auto body repair job. This video takes viewers through the entire process of preparing, sanding, priming, sealing, topcoating, clearcoating, quality-checking, and final detailing. Use the Surface Preparation and Refinishing video and accompanying activities provided in this guide to prepare students for the most effective way to approach auto body repairs, and to familiarize students with terminology used in the auto repair industry.


After viewing the program, students will be able to:

I Demonstrate a basic knowledge of surfacing and refinishing operations and safety procedures.

I Identify the correct tools to use given the task to be performed.

I Identify proper equipment and materials in refinishing.

I Identify specialized finishes.

I Describe procedures for sanding and grit selection.

I List procedures for masking.

I Determine proper procedures for spray painting.

I Explain different types of paints and undercoatings and the procedures for application.

I List automotive detailing procedures.


The primary certifying body for automotive technician training programs is the National Institute for Automotive Service Excellence (ASE). ASE is a non-profit organization established in 1972 by the automotive industry to improve the quality of vehicle repair and service through the voluntary testing and certification of automotive repair technicians. The National Automotive Technicians Education Foundation (NATEF) is a separate non-profit foundation within ASE. The mission of NATEF is to improve the quality of automotive technician training programs nationwide through voluntary certification. The State Departments of Education in all 50 states support ASE/NATEF certification of automotive programs.

National Standards This program correlates with the Program Certification Standards for Automobile Technician Training Programs from the National Institute for Automotive Service Excellence (ASE) and the National Automotive Technicians Education Foundation (NATEF). The content has been aligned with the following educational standards, which reflect the tasks in the ASE Program Certification Standards for Automobile General Service Technician Programs.

Copyright © 2005 SHOPWAR E ® Preparation I Comply with personal and environmental safety practices associated with clothing; respiratory protection; eye protection; hand tools; power equipment; proper ventilation; and the handling, storage, and disposal of chemicals/materials in accordance with local, state, and federal safety and environmental regulations.

Safety Precautions I Select and use the proper personal safety equipment for surface preparation, spray gun and related equipment operation, paint mixing, matching and application, paint defects, and detailing (gloves, suits, hoods, eye and ear protection, etc.).

Surface Preparation I Inspect, remove, store, and replace exterior trim and molding.

I Soap and water wash entire vehicle; use appropriate cleaner to remove contaminants.

I Inspect and identify substrate, type of finish and surface condition; develop a plan for refinishing using a total product system.

I Remove paint finish.

I Dry or wet sand areas to be refinished.

I Featheredge broken areas to be refinished.

I Apply suitable metal treatment or primer.

I Mask trim and protect other areas that will not be refinished.

I Mix primer, primer-surfacer or primer-sealer.

I Apply primer onto surface of repaired area.

I Apply two-component finishing filler to minor surface imperfections.

I Dry or wet sand area to which primer-surfacer has been applied.

I Dry sand area to which two-component finishing filler has been applied.

I Remove dust from area to be refinished, including cracks or moldings of adjacent areas.

I Clean area to be refinished using a final cleaning solution.

I Remove, with a tack rag, any dust or lint particles from the area to be refinished.

I Apply suitable sealer to the area being refinished when sealing is needed or desirable.

I Scuff sand to remove nibs or imperfections from a sealer.

Spray Gun and Related Equipment Operation I Inspect, clean, and determine condition of spray guns and related equipment (air hoses, regulators, air lines, air source, and spray environment).

I Check and adjust spray gun operation for HVLP (high volume, low pressure) or LVLP (low volume, low pressure) guns.

I Set up (fluid needle, nozzle, and cap), adjust, and test spray gun using fluid, air, and pattern control valves.

Paint Mixing, Matching, and Applying I Determine type and color of paint already on vehicle by manufacturer’s vehicle information label.

I Shake, stir, reduce, catalyze/activate, and strain paint according to manufacturer’s procedures.

I Apply finish using appropriate spray techniques (gun arc, gun angle, gun distance, gun speed, and spray pattern overlap) for the finish being applied. 3 I Apply selected product on test and let-down panel in accordance with manufacturer’s recommendations; check for color match.

I Apply single stage topcoat for refinishing.

I Apply basecoat/clearcoat for panel blending or partial refinishing.

I Apply basecoat/clearcoat for overall refinishing.

I Denib, buff, and polish finishes where necessary.

I Identify the types of rigid, semi-rigid or flexible plastic parts to be refinished; determine the materials, preparation, and refinishing procedures.

I Refinish rigid, semi-rigid and flexible plastic parts.

I Clean, condition and refinish vinyl (e.g. upholstery, dashes, and tops).

I Apply multi-stage (tricoat) coats for panel blending or overall refinishing.

I Identify and mix paint using a formula.

I Identify poor hiding colors; determine necessary action.

I Tint color using formula to achieve a blendable match.

I Identify alternative color formula to achieve a blendable match.

General Operations I Identify parts using industry terminology.

2004 Automobile Program Standards, by the National Institute for Automotive Service Excellence (ASE), Copyright 2004 Reprinted with permission.

Language Arts and Communication Standards According to ASE/NATEF standards, the automobile technician must be proficient in the following Language Arts and Communications related academic skills that are embedded in the occupation. The activities and information presented in this program and accompanying teacher’s guide are aligned to the following standards from the National Automotive Technicians Education Foundation from the National Institute for Automotive Service Excellence.

I Request, collect, comprehend, evaluate, and apply oral and written information gathered from customers, associates, and supervisors regarding problem symptoms and potential solutions to problems.

I Identify the purpose for all written and oral communication and then choose the most effective strategies for listening, reading, speaking, and writing to facilitate the communication process.

I Adapt a reading strategy for all written materials, e.g. customer’s notes, service manuals, shop manuals, technical bulletins, etc., relevant to problem identification, diagnosis, solution, and repair.

I Use study habits and techniques, i.e. previewing, scanning, skimming, taking notes, etc., when reviewing publications (shop manuals, references, databases, operator’s manuals, and text resources) for problem solving, diagnosis, and repair.

I Write clear, concise, complete, and grammatically accurate sentences and paragraphs.

I Write warranty reports and work orders to include information regarding problem resolution and the results of the work performed for the customer or manufacturer.

I Follow all oral/written directions that relate to the task or system under study.

I Comprehend and apply industry definitions and specifications to diagnose and solve 4 problems in all automotive systems and components of the automobile and light truck.

I Comprehend and use problem-solving techniques and decision trees that are contained in service manuals and databases to determine cause-and-effect relationships.

I Use the service manual to identify the manufacturer’s specifications for system parameters, operation, and potential malfunctions.

I Supply clarifying information to customers, associates, parts supplier, and supervisors.

Standards for the English Language Arts, by the International Reading Association and the National Council of Teachers of English, Copyright 1996 by the International Reading Association and the National Council of Teachers of English. Reprinted with permission.

Technology Standards The activities in this Teacher’s Guide were created in compliance with the following National Education Technology Standards from the National Education Technology Standards Project.

The content has been aligned with the following educational standards and benchmarks.

I Use a variety of media and formats to communicate information and ideas effectively to multiple audiences.

I Use telecommunications to collaborate, publish, and interact with peers, experts, and other audiences.

I Use productivity tools to collaborate in constructing technology-enhanced models, prepare publications, and produce other creative works.

I Use technology tools to enhance learning, increase productivity, and promote creativity.

I Use technology to locate, evaluate, and collect information from a variety of sources.

The National Education Technology Standards reprinted with permission from the International Society for Technology Education.


The finish on any autobody repair is the final touch and is a beautiful thing when done correctly. However, when it is applied incorrectly, it can mean a lot of extra work! So what do you need to know to ensure that the finish turns out perfectly?

This program will use a vehicle with a panel repair to demonstrate the entire process of preparing, sanding, priming, sealing, topcoating, clearcoating, quality-checking, and final detailing. It will also demonstrate a total refinish. After viewing this video and completing some of the learning activities included in this guide, students will be better prepared to properly complete surface preparation and refinishing, and incorporate industry terminology in order to communicate effectively with coworkers, parts suppliers, and insurance adjusters.


Topic 1: Preliminary Preparation & Refinishing Process This section of the program describes the preliminary preparation required for finishing an autobody repair. Students will learn the importance of cleaning before painting, what to look for and how to evaluate what must be done to a surface before refinishing, how to evaluate the existing finish, and color matching.

Topic 2: Surface Preparation This section of the program describes procedures for preparing a surface for refinishing.

Students will learn how to properly remove cracked or blistered paint, how to use chemical stripper, proper blasting, sanding, and grinding techniques, how to apply primer-surfacer, and how to properly “mask” a vehicle for painting.

Topic 3: Applying the Finish This section describes the procedures for applying a final finish to an auto body repair.

Students will learn the four main considerations when applying the final finish, safety procedures for spraying finishes, how to test and adjust spray guns, and how to correctly apply sealer, color, and clear coats.

Topic 4: Detailing This section of the program discusses the imperfections to look for after a new finish is applied, how to correct those imperfections, and what procedures should be followed to thoroughly clean and prepare the vehicle for delivery back to its owner.


I When preparing a vehicle for refinishing, it is important to apply a wax remover and degreaser. Paint will not adhere to a surface with wax, silicones, or grease.

I One thing to check before refinishing is how much paint buildup exists on the vehicle.

Typically, the factory finish plus one additional refinish will be slightly under 12 mils, or 12 thousandths of an inch. Paint build-up should be limited to 12 mils. If it becomes thicker than 12 mils, the paint has a tendency to crack.

I Before refinishing, you need to find out what kind of finish the car has and match the color and the type of paint. The vehicle’s identification plate contains the manufacturer’s paint codes as well as the type of finish. The ID plate is located in different places for different makes and models of vehicles.

I Paint colors vary slightly from batch to batch even with precise measuring and mixing. Over time, a vehicle’s finish can fade. Therefore, it is important to create a test panel to check the color match before refinishing the vehicle.

I Paint needs to be thinned to decrease its viscosity or thickness. If paint is too thick or viscous, it won’t flow or atomize properly. If it’s too thin, it won’t cover and will tend to create drips.

I Blasting with abrasives will quickly remove loose paint and reveal any underlying rust.

Abrasives that can be used include sand, plastic beads, soda, even walnut shells. Blasting with sand may damage thinner steel panels, aluminum, or plastic. Using soda, walnut shells, or plastic media instead of sand makes blasting safe for all surfaces.

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