Figure 3.42 A full set of general and assembly tools

(Facom Tools Ltd )

Hand and power tools 111

Figure 3.43Air power chisel and accessories (Black and Decker Ltd )

112Repair of Vehicle Bodies

(14 SWG) or 3 mm (10 SWG) aluminium, which

more than covers the automobile requirements.

The shear is used extensively in the cutting of

light materials for the construction of new vehicles,

but also plays an important role in the

removal of damaged sections in crash repairs, as

it leaves a nice neat cut and there is no risk of

flame damage as with the more traditional methods

of oxy-acetylene cutting.

Pneumatic metal shear

This tool uses the same action as snips, having

two fixed blades and one blade moving vertically

between them (Figure 3.46). This central movable

blade cuts out a thin ribbon of metal which coils

and is discarded. Cutting can be started from the

edge of the panel, or from any point on the panel

surface using a predrilled hole large enough to

insert the central cutting blade. Radiuses up to

in (200 mm) can be cut on material up to 1.2 mm

(18 gauge). Care must be taken not to damage the

panel surface by causing buckling during the

cutting action.

Figure 3.45Air shears (Desoutter Automotive Ltd )

Figure 3.46Pneumatic metal shear (Desoutter

Automotive Ltd )

Figure 3.44Metal cutting shears (Black and

Decker Ltd )

Metal cutting nibbler

This is a portable nibbler which uses a punch and

die (Figure 3.47). The actual cutting is done by the

edge of the punch which is reciprocated at high

speed, leaving a slot or channel in the metal.

Cutting can be commenced from the panel edge, or

from a hole predrilled in the panel surface to allow

entry of the punch. Allowances must be made for

the width of the cut and, when accurate positioning

of the cut is essential, templates can be used as a

guide.

Hand and power tools 113

3.21 Power saw

This is a high-speed pneumatic tool using

interchangeable, reciprocating hacksaw blades

(Figure 3.48). It is able to cut from straight lines

to tight curves. Cutting can be started anywhere on

a panel without the need for pilot holes. Single- or

double-skinned panel assemblies can be easily cut

owing to the short blade stroke. The tool can be used

to cut a wide variety of materials including lightgauge

steel, aluminium, reinforced glass fibre, wood

and hardboard. Its fine cut is ideally suited for panel

replacement where joints have to be cut and welded.

Another power saw is the rotary or circular saw

(Figure 3.49).

Figure 3.47Metal cutting nibbler (Desoutter

Automotive Ltd )

Figure 3.48Power saw (Desoutter Automotive Ltd )

Figure 3.49Circular metal cutting saw (Desoutter

Automotive Ltd )

Figure 3.50General duty drill (Black and Decker Ltd )

3.22 Power drills

Standard drills

There are two types of power drill used in the

bodyshop: the majority are usually electrically

driven and require a 13 A electrical power point

(Figure 3.50), while the others are air powered and

require a compressor and air points (Figure 3.51).

The most popular sizes in common use are the in

(6.3 mm) pistol drill, and the in and in (9.5 mm

and 12.6 mm) heavy-duty machines. Drills are used

mostly for drilling out spot welds along damaged

panels which need removing, and also for drilling

out broken rivets and bolts. As well as the standard

size drills there is a special drill called an angle

drill, which is extremely useful in bodywork as it

can be used in confined spaces and enables many

otherwise impossible drilling tasks to be carried

out (Figure 3.52).

114Repair of Vehicle Bodies

Cordless drill

This uses an energy pack to supply the power, with

a fast charge facility for recharging from a mains

supply (Figure 3.53). It can be single speed or two

speed, and can drill up to 3 mm steel. When fitted

with a reversible adjustable clutch this tool can

be used as a power screwdriver, thus making it a

tremendously versatile piece of equipment, especially

in the body building industry.

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