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Transportation · course plan

⚠ Pending professional review

This course plan, its lessons and its assessments has not yet been verified by a certified examiner or master technician in the trade or by a certification or approval body. It is a study draft and may contain errors. Do not use it as instructions for work on a job site or on live equipment. Always follow your instructor, your supervising professional, and current official references and regulations.

VoTechWorks program approval and accreditation are still in progress. Credentials are issued only by the certifying bodies named in each program, after their own exams.

Auto Body & Collision

9 courses · 1,800 clock hours · 9–12 mo full-time. Grading is competency-based: each course requires the written exam, a competent skills demonstration with zero safety faults, a signed log, and a passed safety audit; percentage weights only rank performance above the competency floor.

~~$20,260~~ COMPLIMENTARYprogram tuition

9courses

79lessons

1,800hours

31assessments

Development progressPlanCourses, lessons and assessments written for this tradeLessons79 of 79 lesson pages writtenPractice621 practice questionsResources118 reference entries (study list)Review0 lesson pages reviewed by a licensed professional

Study now: 79 lesson pages are open (lesson titles below are links).

TRN-AUTO25-01 Universal core

Universal Core: Safety, Math, Communication & Career for Auto Body & Collision

148 hr · ~~$1,185~~ COMPLIMENTARY

This course builds the foundational knowledge every collision repair technician needs before touching a vehicle: shop safety, hazard recognition, OSHA standards, trade mathematics, measurement, technical reading, digital tools, and professional career skills. Lessons are contextualized to auto body and collision work throughout, so students immediately see how each skill applies on the shop floor. Successful completion prepares students to work safely, read repair documentation accurately, and meet the professional expectations of I-CAR and ASE credential holders.

Outcomes

Demonstrate safe shop practices including proper PPE selection, OSHA Hazard Communication (HazCom) compliance, and lockout/tagout procedures specific to auto body equipment.
Pass an OSHA 10-Hour General Industry or Construction outreach course and demonstrate basic first-aid and CPR skills to the satisfaction of a recognized training provider.
Apply trade mathematics—including fractions, decimals, percentages, ratio and proportion, unit conversion, and geometric area and volume calculations—to collision repair tasks such as reading body specifications and mixing refinish materials.
Read and interpret collision repair documents including OEM repair procedures, vehicle identification number (VIN) decoding, estimating sheets, and material safety data sheets (SDS).
Use digital tools common to the trade—shop management software, OEM information portals, and digital measuring references—to locate and record vehicle repair information accurately.
Present a professional resume, demonstrate workplace communication skills, and articulate how I-CAR ProLevel and ASE B-series credentials advance a collision repair career.

Course text

How the course runs. 7 blocks: Shop Hazards, PPE, and OSHA HazCom in the Collision Shop; Lockout/Tagout, Electrical Safety, and Compressed-Air Safety; OSHA 10-Hour and First Aid / CPR; Trade Math: Measurement, Fractions, Decimals, and Unit Conversion; Trade Math: Ratio, Proportion, Percentage, Area, and Volume for the Collision Shop; Technical Reading: OEM Procedures, VIN Decoding, and Repair Documentation; Digital Tools, Professional Communication, Resume, and Career Readiness.

What competent looks like. Demonstrate safe shop practices including proper PPE selection, OSHA Hazard Communication (HazCom) compliance, and lockout/tagout procedures specific to auto body equipment. Pass an OSHA 10-Hour General Industry or Construction outreach course and demonstrate basic first-aid and CPR skills to the satisfaction of a recognized training provider. Apply trade mathematics—including fractions, decimals, percentages, ratio and proportion, unit conversion, and geometric area and volume calculations—to collision repair tasks such as reading body specifications and mixing refinish materials. Read and interpret collision repair documents including OEM repair procedures, vehicle identification number (VIN) decoding, estimating sheets, and material safety data sheets (SDS). Use digital tools common to the trade—shop management software, OEM information portals, and digital measuring references—to locate and record vehicle repair information accurately. Present a professional resume, demonstrate workplace communication skills, and articulate how I-CAR ProLevel and ASE B-series credentials advance a collision repair career.

Lessons · 7 blocks

#	Lesson	Hr	Type	Objective	Activities	Materials	Check
1	Shop Hazards, PPE, and OSHA HazCom in the Collision Shop	24	theory	Students will identify the major hazard categories present in an auto body shop, select and inspect correct PPE for each hazard, and explain OSHA Hazard Communication requirements including SDS access and chemical labeling.	Guided walk-through of the collision lab: students use a provided hazard-identification checklist to locate and categorize at least 15 specific hazards (chemical, electrical, ergonomic, fire, compressed air, UV/IR radiation) and record corrective actions for each. SDS scavenger hunt: each student is assigned three common shop chemicals (e.g., isocyanate-based clearcoat, body filler catalyst, weld-through primer) and must locate their SDS, identify the GHS pictograms, PPE requirements, first-aid measures, and spill-response procedures, then brief the class in two minutes. PPE station rotation: students try on and inspect respirators (half-face APF-10, supplied-air), nitrile and chemical-resistant gloves, face shields, hearing protection, and safety footwear; they practice a respirator seal check and record whether each item passes or fails inspection on a standardized form.	OSHA 29 CFR 1910 Hazard Communication standard (current edition), NIOSH respirator selection guide, assorted PPE samples, shop SDS binder, GHS label examples, hazard-identification checklist, PPE inspection form	Written PPE-and-hazard quiz of 20 questions; student must score 75% or higher. Instructor also verifies correct respirator fit-check technique by direct observation using a signed competency checklist.
2	Lockout/Tagout, Electrical Safety, and Compressed-Air Safety	16	demo	Students will perform a six-step lockout/tagout procedure on a shop tool, identify electrical hazards specific to collision equipment, and demonstrate safe compressed-air practices including pressure limits and blow-gun handling.	Instructor demonstrates LOTO on a frame-straightening machine and a MIG welder; students then perform the same procedure in pairs on the same equipment while instructor observes each team and gives real-time corrective feedback. Electrical hazard mapping: using a shop wiring diagram, students identify required circuit ratings for spray booths, welders, and frame machines, and mark locations where ground-fault circuit interrupter (GFCI) protection is required. Compressed-air safety drill: students practice connecting and disconnecting air hoses using safety whip-checks, setting regulator pressure to manufacturer spec for a DA sander, and directing blow-gun airflow away from skin; they document each step on a safety checklist.	OSHA LOTO standard (29 CFR 1910.147) summary card, lockout padlocks and tags (one set per student pair), hasp, shop electrical diagram, GFCI tester, air-compressor and regulator, blow gun with OSHA-compliant tip, whip-checks, compressed-air safety checklist	Instructor-signed LOTO performance checklist: all six steps completed in correct order with zero omissions = pass. Any skipped step = automatic repeat before proceeding.
3	OSHA 10-Hour and First Aid / CPR	16	theory	Students will complete an OSHA 10-Hour outreach course and demonstrate adult CPR, AED use, and wound-control first aid to the standard of a recognized training provider.	Attend and complete all modules of the OSHA 10-Hour General Industry or Construction outreach course delivered by an authorized OSHA outreach trainer; students document attendance and receive the OSHA 10 card upon successful completion. First-aid and CPR skills session led by an American Red Cross or American Heart Association certified instructor: students practice hands-only CPR on a manikin, AED pad placement and device use, bleeding control with direct pressure and tourniquet application, and recognition of shock. Scenario walk-through: small groups respond to three simulated shop incidents (chemical splash to eyes, arc-flash burn, worker unresponsive at a frame machine) by identifying the hazard, calling for help, and providing appropriate first aid while a classmate records response steps.	OSHA 10-Hour outreach materials (trainer-provided), CPR/AED manikins, AED trainer unit, gloves, face shields, wound-care supplies (gauze, tourniquets), scenario cards	OSHA 10 card issued by authorized trainer = pass. CPR/First Aid: skills sign-off by certified instructor using provider's competency checklist. Both must be completed to pass this lesson.
4	Trade Math: Measurement, Fractions, Decimals, and Unit Conversion	22	theory	Students will accurately perform arithmetic operations with fractions and decimals, convert between US customary and metric units, and read both a standard tape measure and a digital caliper to the nearest millimeter and 1/32 inch.	Measurement lab: each student measures ten body panel dimensions listed on a sample OEM dimension chart using a steel tape measure and a digital caliper, records readings in both inches and millimeters, and checks their readings against the answer key; discrepancies greater than 1 mm are remeasured. Math problem set of 30 trade-contextualized problems: calculating how many milliliters of hardener to add to a given volume of filler, converting panel gap measurements from inches to millimeters, and computing the area of a roof panel to estimate material usage; students complete problems individually and then compare answers with a partner. Error analysis: instructor presents five 'technician math mistakes' drawn from real estimating errors (wrong unit, dropped decimal, incorrect ratio) and students identify the error, explain its consequence to repair quality or cost, and calculate the correct answer.	Steel tape measure (metric/imperial), digital caliper, OEM dimension chart sample, calculator, trade math worksheet, unit-conversion reference card, pencil and graph paper	Math skill quiz of 25 problems (mix of measurement, conversion, and arithmetic); passing score is 75%. Measurement accuracy verified by instructor spot-check of caliper readings: readings within ±0.5 mm = pass.
5	Trade Math: Ratio, Proportion, Percentage, Area, and Volume for the Collision Shop	18	practice	Students will apply ratio and proportion to calculate paint mix ratios, use percentage to compute material waste and markup, and calculate surface area and volume to determine refinish material quantities.	Paint-mixing exercise: given manufacturer-supplied mixing ratios for three different refinish systems, students calculate the exact volumes of each component needed to produce a specified total volume, mix the components in graduated cups (using water tinted with food coloring for safety), and verify the ratio by measuring back with a graduated cylinder. Estimating worksheet: students use the dimensions of a sample sedan's hood, door, and quarter panel to calculate surface area, then apply a published material coverage rate to determine the number of ounces of refinish product needed; they compute a 15% waste allowance and check their work against an instructor answer key. Group problem challenge: teams of three compete to correctly solve a set of five ratio/proportion/percentage problems pulled from past I-CAR and ASE study materials (used for content alignment only); the first team to post correct, clearly shown work on the whiteboard explains their method to the class.	Graduated mixing cups (metric), graduated cylinder, food coloring, refinish system tech sheet with mix ratios, sample vehicle dimension sheet, calculators, whiteboard and markers, I-CAR/ASE study-material excerpts for problem content	Skill demonstration: student correctly calculates and measures out a two-component mix ratio within ±5% of target volume as verified by instructor with graduated cylinder. Follow-up written check of 10 calculation problems; 75% correct to pass.
6	Technical Reading: OEM Procedures, VIN Decoding, and Repair Documentation	26	theory	Students will decode a 17-character VIN to identify vehicle make, model, year, engine, and plant; locate the correct OEM structural repair procedure for a given vehicle and damage type; and accurately read and annotate an estimating worksheet.	VIN decoding lab: each student receives a printed VIN for a different vehicle and uses the NHTSA VIN decoder and a physical reference card to identify all 17 characters, then cross-references the result against an OEM parts catalog to confirm body style and restraint system type; students record findings on a structured worksheet. OEM repair procedure retrieval: using a shop subscription to an OEM information portal (e.g., alldata, Mitchell, or a manufacturer direct site), students locate the structural repair procedure for a quarter-panel replacement on an assigned vehicle, print or screenshot the procedure, highlight the critical steps, and write a one-paragraph summary of the required steps in their own words. Estimating sheet annotation: students receive a completed damage estimate for a moderate-collision repair; they identify and label each section (labor operations, parts, sublet, paint materials, totals), flag any line item that references an OEM procedure, and calculate whether the listed part quantities match the damage described using the VIN-decoded parts lookup.	Sample 17-character VINs (one per student, varied), NHTSA VIN decoder access (online), OEM information portal subscription, printed estimating sheet samples, parts catalog excerpts, annotation worksheet, highlighters	VIN decode accuracy: all 17 characters correctly interpreted = pass (any error requires rework). OEM procedure retrieval: instructor reviews student summary for accuracy against actual procedure; all critical steps present = pass. Estimating annotation graded on rubric; 75% of items correctly identified and labeled to pass.
7	Digital Tools, Professional Communication, Resume, and Career Readiness	26	field	Students will navigate shop management software and OEM information portals to retrieve repair data, compose a professional written communication appropriate to the trade, build a resume targeting a collision repair technician position, and articulate the career value of I-CAR ProLevel and ASE B-series credentials to an industry guest.	Digital tools scavenger hunt: using the shop's estimating or management software and an OEM portal, students complete a guided task sheet requiring them to open a repair order, locate a labor time, find a parts price, retrieve a torque specification, and print a supplement request; completed task sheets are reviewed for accuracy. Professional communication exercise: students draft a formal email to a parts supplier disputing a wrong part delivery, applying trade-specific terminology correctly; they also practice a phone script for updating a customer on repair status; a peer edits each draft for clarity and professionalism before the instructor evaluates the final version. Career panel and resume workshop: a licensed I-CAR instructor or ASE-certified technician joins as a guest; students ask prepared questions about career pathways, credential maintenance, and employer expectations; following the panel, students build or update a resume using a trade-specific template, listing any credentials in progress, tool inventory, and relevant experience, then receive peer and instructor feedback.	Shop management or estimating software workstation, OEM portal access, email-drafting template, professional communication rubric, resume template for collision repair technicians, list of I-CAR and ASE credential descriptions, guest speaker (I-CAR instructor or ASE-certified technician)	Digital scavenger hunt: all required data fields correctly retrieved and recorded (100% accuracy required; student retries any missed item). Email draft evaluated on rubric covering accuracy, tone, and correct trade terminology; 75% score to pass. Resume evaluated for completeness and professional format; instructor sign-off required before student proceeds to Course 2.

Assessments

Assessment	Type	Weight	Pass standard	Method & rubric
Safety and Regulatory Knowledge Exam	Written exam	25%	75% correct (38 of 50 questions)	A 50-question multiple-choice and short-answer written exam covering OSHA HazCom, GHS labeling, SDS sections, PPE selection, LOTO procedures, compressed-air safety, electrical hazards in the collision shop, fire extinguisher classes, and OSHA 10 core content. Questions are aligned to I-CAR ProLevel safety module topics and ASE B-series safety knowledge areas. Accuracy · Safety · Communication · Professionalism
Trade Math and Technical Reading Exam	Written exam	25%	75% correct (30 of 40 problems/questions)	A 40-item written examination combining trade math problems (unit conversion, ratio/proportion, area/volume, percentage) and technical-reading questions (VIN decoding, SDS interpretation, estimating sheet analysis, OEM procedure comprehension); all problems are set in realistic collision repair contexts to mirror the applied-knowledge format of ASE B-series exams. Accuracy · Safety · Communication · Professionalism
Integrated Safety and Documentation Portfolio	Project	25%	Instructor rubric score of 75% or higher across all four sections; OSHA 10 card and CPR/First Aid card must be present	Students submit a portfolio containing: (1) the completed shop-hazard walk-through checklist with corrective actions, (2) their OSHA 10 completion card and CPR/First Aid provider card, (3) the VIN decode and OEM procedure retrieval worksheet for an assigned vehicle, and (4) their final professional resume. Each section is scored on a four-point rubric for accuracy, completeness, and professional presentation. Accuracy · Safety · Communication · Professionalism
Career Readiness and Safety Oral Defense	Oral / panel	25%	Pass on all four rubric dimensions (accuracy, vocabulary, professionalism, self-assessment); any 'fail' dimension requires a targeted re-defense within one week	In a ten-minute structured oral session, the student answers four questions drawn randomly from a bank covering shop safety decisions, PPE rationale, trade math reasoning, and I-CAR/ASE credential pathways; an industry-connected evaluator (ideally the career-panel guest) joins the instructor to score the student on technical accuracy, use of correct trade vocabulary, professional demeanor, and the ability to self-identify areas for continued growth. Accuracy · Safety · Communication · Professionalism

TRN-AUTO25-02 Trade course

Frame Straightening and Structural Repair

205 hr · ~~$2,950~~ COMPLIMENTARY

This course develops competency in diagnosing, measuring, and restoring collision-damaged vehicle frames and unibody structures to manufacturer specifications using industry-standard equipment and procedures. Students learn to read datum planes, use dedicated measuring systems, operate frame-straightening benches and pulling equipment, and verify repairs meet OEM tolerances. Lessons map directly to I-CAR ProLevel structural repair knowledge areas and ASE B-series (B4 Non-Structural Analysis and Damage Repair / B3 Structural Analysis and Damage Repair) exam content.

Outcomes

Perform a complete structural damage analysis using a dedicated measuring system and identify all deviations from published OEM datum and tolerance specifications.
Set up and safely operate a frame-straightening bench with anchoring and pulling equipment to restore a collision-damaged unibody or body-on-frame vehicle to within OEM tolerances.
Identify and repair damaged structural sections using sectioning procedures, including proper weld placement and corrosion protection, following OEM repair procedures.
Recognize the limits of repair on severely damaged structural components and document when replacement rather than repair is required per OEM and I-CAR guidelines.
Apply all required personal protective equipment and lockout/tagout procedures when working with hydraulic pulling equipment, high-strength steel, and welding operations in the frame repair environment.
Produce repair documentation—including pre- and post-repair measurement printouts, damage diagrams, and corrosion-protection records—meeting industry estimating and quality-control standards.

Course text

How the course runs. 12 blocks: Vehicle Structure Fundamentals: Unibody vs. Body-on-Frame; Damage Analysis: Recognizing Structural Damage Types; Shop Safety for Frame Work: PPE, Lockout/Tagout, and Hazard Control; Measuring Systems: Dedicated, Tram, and Electronic; Frame-Straightening Equipment: Bench Setup and Anchoring; Pulling Operations and Monitoring Measurements; High-Strength Steel and Advanced Materials in Modern Structures; Structural Component Sectioning Procedures; Corrosion Protection After Structural Repair; Suspension, Steering, and Mechanical Component Inspection After Structural Repair; Repair Documentation and OEM Procedure Research; Integrated Frame Repair Practical: Full Structural Repair Sequence.

What competent looks like. Perform a complete structural damage analysis using a dedicated measuring system and identify all deviations from published OEM datum and tolerance specifications. Set up and safely operate a frame-straightening bench with anchoring and pulling equipment to restore a collision-damaged unibody or body-on-frame vehicle to within OEM tolerances. Identify and repair damaged structural sections using sectioning procedures, including proper weld placement and corrosion protection, following OEM repair procedures. Recognize the limits of repair on severely damaged structural components and document when replacement rather than repair is required per OEM and I-CAR guidelines. Apply all required personal protective equipment and lockout/tagout procedures when working with hydraulic pulling equipment, high-strength steel, and welding operations in the frame repair environment. Produce repair documentation—including pre- and post-repair measurement printouts, damage diagrams, and corrosion-protection records—meeting industry estimating and quality-control standards.

Lessons · 12 blocks

#	Lesson	Hr	Type	Objective	Activities	Materials	Check
1	Vehicle Structure Fundamentals: Unibody vs. Body-on-Frame	14	theory	Students will correctly classify vehicle structural designs and identify primary structural members and their crash-management functions from OEM diagrams.	Annotate a set of OEM structural diagrams for at least three vehicle platforms, labeling crush zones, torque boxes, pillars, rails, and rocker panels. Compare and contrast load paths in a unibody sedan versus a body-on-frame truck using cutaway models or manufacturer training aids, then present findings to the class. Complete a written identification quiz on structural component names and functions using I-CAR structural training materials, targeting 80% or higher.	OEM service information (dealer portals or Mitchell/All Data), I-CAR structural course materials, vehicle cutaway models or posters, whiteboard	Written quiz on structural component identification and crash-management function; pass mark 80%
2	Damage Analysis: Recognizing Structural Damage Types	16	demo	Students will identify and categorize all five categories of collision damage—sway, mash, diamond, twist, and collapse—on actual collision-damaged vehicles.	Walk through an instructor-led visual inspection of three collision-damaged vehicles, naming damage categories aloud and sketching damage diagrams for each. Use a tram gauge and tape measure to perform a preliminary cross-check on a damaged vehicle and record deviations on a damage-analysis worksheet. Review two OEM position statements on structural damage assessment and list procedural requirements that affect repair decisions.	Collision-damaged vehicles (minimum 2), tram gauge, tape measure, OEM position statements, damage-analysis worksheets, I-CAR damage analysis reference	Instructor observation of damage-category identification on all three vehicles; all five damage types correctly named and sketched on worksheets; 80% accuracy
3	Shop Safety for Frame Work: PPE, Lockout/Tagout, and Hazard Control	12	theory	Students will demonstrate correct PPE selection, apply OSHA-compliant lockout/tagout procedures for hydraulic and pneumatic equipment, and identify chemical hazards associated with frame repair operations.	Perform a guided lockout/tagout simulation on a hydraulic pulling tower following the shop's written energy-control procedure, then have a partner attempt to energize the equipment to verify isolation. Match SDS sections to specific hazards (rust inhibitors, weld-through primer, corrosion protection coatings) on a provided SDS-reading worksheet. Inspect and correctly don all required PPE for frame-straightening operations—safety glasses, face shield, gloves, hearing protection, and steel-toed footwear—and explain to the instructor why each item is required.	Shop LOTO locks and tags, energy-control procedure cards, SDS binders, full PPE sets, OSHA 10 reference materials, safety audit checklist	100% correct execution of LOTO procedure; SDS worksheet scored at 100%; PPE inspection passed with no deficiencies—safety competency requires 100% pass
4	Measuring Systems: Dedicated, Tram, and Electronic	18	demo	Students will set up and operate at least two types of structural measuring systems and record vehicle measurements to within ±1 mm of instructor-verified values.	Set up a dedicated measuring system on an undamaged vehicle using the manufacturer's reference chart, attach all gauges, and read control-point dimensions aloud with instructor verification. Use an electronic measuring system (such as a laser or computerized frame machine measuring function) to capture a full set of datum readings and generate a printed report. Compare tram-gauge cross-checks with dedicated-system readings on the same vehicle and calculate the deviation; discuss why discrepancies occur and how they affect repair planning.	Dedicated measuring system (e.g., Car-O-Liner, Celette, or equivalent), tram gauge, electronic measuring system or frame machine with measurement software, OEM datum charts, measurement worksheets	Measurement printout or recorded worksheet must show all readings within ±1 mm of instructor-verified values; re-measure until standard is met
5	Frame-Straightening Equipment: Bench Setup and Anchoring	18	demo	Students will correctly set up a frame-straightening bench—including pinch-weld clamps, universal fixtures, and anchor points—for a specific vehicle following equipment manufacturer procedures.	Read the equipment manufacturer's bench setup guide and identify the correct anchor pinch-weld locations for a designated vehicle using OEM sill specifications. Under instructor supervision, install pinch-weld clamps and anchor chains, torque them to specification, and perform a pull-test verification before any pulling load is applied. Document the bench setup with photographs and a written equipment setup checklist, noting clamp positions, chain angles, and anchor torque values.	Frame-straightening bench (e.g., Chief, Car-O-Liner, Spanesi, or equivalent), pinch-weld clamps, anchor chains, torque wrench, equipment manufacturer manual, setup checklist form	Instructor evaluation of bench setup using a scored checklist; all anchor points, clamp positions, and chain angles must meet equipment manufacturer specifications before any pulling begins; 100% critical safety items, 80% overall
6	Pulling Operations and Monitoring Measurements	22	lab	Students will execute a multi-pull repair sequence on a collision-damaged vehicle, monitoring measurements after each pull and adjusting pull direction and force to return structure to within OEM tolerances.	Plan a pulling sequence for an assigned damaged vehicle by identifying primary and secondary damage, then sketch a pull plan with pull direction, attachment points, and restraint locations before touching the equipment. Perform a minimum of three progressive pulls, stopping after each to re-measure with the dedicated system, record deviations on the monitoring sheet, and adjust the setup as needed. When structure is within tolerance, generate a final measurement printout and compare pre- and post-repair readings as a class debrief activity.	Frame-straightening bench with hydraulic pulling tower, dedicated measuring system, pull chains and clamps, heat gun (if instructor-approved for mild steel), pre/post measurement worksheets, OEM tolerance specifications	Post-repair measurement printout must show all control points within OEM published tolerances (typically ±3 mm); pull plan evaluated by instructor before work begins; written monitoring log complete
7	High-Strength Steel and Advanced Materials in Modern Structures	14	theory	Students will differentiate between mild steel, high-strength steel (HSS), ultra-high-strength steel (UHSS), and aluminum structural applications and state correct OEM repair procedures for each material type.	Review three OEM position statements or repair procedures that specify heat limits, repair restrictions, or replacement requirements for UHSS components and summarize them on a comparison chart. Identify substrate types on a vehicle door ring or B-pillar assembly using a material identification card or OEM service information, labeling each zone by steel grade. Discuss as a group why straightening UHSS with heat above OEM limits compromises crash performance, referencing specific tensile and yield strength changes described in I-CAR training materials.	I-CAR advanced materials training resources, OEM position statements (Honda, GM, Ford, or other available), vehicle door ring display or poster, material identification reference cards	Individual written summary chart graded for accuracy on material types, heat limits, and repair vs. replace decisions; pass mark 80%
8	Structural Component Sectioning Procedures	22	lab	Students will perform a structural rail section repair following OEM or I-CAR sectioning guidelines, including correct cut location, joint preparation, weld sequencing, and post-weld inspection.	Using OEM or I-CAR sectioning guidelines, mark the correct cut location on a rail section mockup, avoiding factory welds and high-stress areas, then have the instructor verify before cutting. Prepare the mating surfaces, fit the replacement section, and complete the required plug welds and butt welds in the specified sequence using the shop's MIG welder, applying weld-through primer to lap surfaces before assembly. Inspect the completed section for weld penetration, profile, and alignment using a straight edge and measuring system; record results on a sectioning inspection form.	Rail section mockups or scrap vehicle sections, MIG welder (set to manufacturer-recommended settings for substrate gauge), weld-through primer, grinder, cut-off wheel, straight edge, sectioning inspection form, OEM/I-CAR sectioning guidelines	Sectioning inspection form reviewed by instructor; weld placement within OEM-specified zones, weld-through primer applied to all lap surfaces, alignment within ±2 mm; pass mark 80% on scored rubric
9	Corrosion Protection After Structural Repair	12	demo	Students will apply the correct sequence of corrosion-protection materials—weld-through primer, cavity wax, seam sealer, and anti-corrosion coating—to a completed structural repair to meet OEM and I-CAR standards.	Review the corrosion-protection section of an OEM repair procedure and create a sequencing checklist for a specific repair type (e.g., rocker panel sectioning). Under instructor demonstration, apply weld-through primer before assembly, seam sealer to all seams after welding, and interior cavity wax through access holes using the appropriate applicator wand. Inspect a completed demo panel for missed seams or thin coverage using a flashlight and probe; compare to the OEM procedure checklist and identify any deficiencies.	Weld-through primer, seam sealer (OEM-approved type), cavity wax and applicator wand, anti-corrosion coating, repair panel demo piece, OEM corrosion-protection procedures, inspection checklist	Completed corrosion-protection checklist signed by instructor; all seams sealed, all cavities coated, no bare metal visible at any weld zone; pass mark 100% on critical items
10	Suspension, Steering, and Mechanical Component Inspection After Structural Repair	14	demo	Students will perform a post-repair inspection of suspension mounting points, steering geometry references, and adjacent mechanical systems to identify conditions requiring wheel alignment, part replacement, or further repair.	Using a vehicle that has undergone a simulated front-rail repair, inspect all suspension mounting holes and subframe mounting locations for elongation, cracking, or misalignment using a gauge pin set and visual inspection. Review an alignment specification sheet and explain which alignment angles are most likely affected by front-rail damage, recording findings on an inspection form. Identify at least three mechanical components (e.g., tie rod, control arm, sway bar end link) that must be inspected or replaced after specific types of structural damage and note the relevant OEM requirements.	Repaired or demonstration vehicle, gauge pin set, tape measure, alignment specification reference, suspension inspection form, OEM service information	Completed suspension inspection form reviewed by instructor; all mounting locations checked and documented; correct identification of required alignment and component inspections; pass mark 80%
11	Repair Documentation and OEM Procedure Research	14	theory	Students will research and compile a complete OEM-compliant structural repair package—including procedure documents, position statements, and pre/post measurement records—for an assigned collision scenario.	Access an OEM information system (Mitchell, AllData, or direct OEM portal) and locate the structural repair procedure, sectioning guidelines, and any applicable position statements for an assigned vehicle and damage scenario. Assemble a repair package folder containing the damage diagram, pre-repair measurements, procedure printouts, material specifications, and a corrosion-protection plan; organize it using an industry estimating format. Peer-review a classmate's repair package against a scoring rubric, providing written feedback on missing procedures, incorrect material specifications, or incomplete measurement documentation.	Computers with OEM information system access (Mitchell, AllData, or direct portal), printer, repair package rubric, industry estimating format guide (e.g., CCC or Audatex documentation conventions)	Repair package evaluated against rubric; must include all required documents, correct vehicle-specific procedures, and complete pre/post measurement records; pass mark 80%
12	Integrated Frame Repair Practical: Full Structural Repair Sequence	29	lab	Students will complete a full structural repair sequence—analysis, measuring, straightening, sectioning if required, corrosion protection, and documentation—on a collision-damaged vehicle to OEM tolerances with full safety compliance.	Perform a complete damage analysis and write a repair plan with pull sequence, material list, and step-by-step procedure before touching the vehicle; obtain instructor sign-off on the plan. Execute all repair operations over multiple sessions: bench setup and anchoring, pulling with continuous measurement monitoring, any required sectioning, and full corrosion protection application. Produce and present a final repair package including pre- and post-repair measurement printouts, completed corrosion-protection checklist, damage diagram, and a five-minute oral explanation of repair decisions to the instructor.	Collision-damaged vehicle, frame-straightening bench, dedicated measuring system, MIG welder, full PPE, corrosion-protection materials, all repair documentation forms, camera for documentation photographs	Post-repair measurement printout within OEM tolerances; complete repair documentation package; oral defense evaluated on rubric covering damage analysis, procedure selection, safety compliance, and corrosion protection; pass mark 80% overall, 100% on all safety items

Assessments

Assessment	Type	Weight	Pass standard	Method & rubric
Structural Knowledge Exam	Written exam	25%	80% or higher	A 60-question written exam covering vehicle structural design, damage category identification, high-strength steel material properties and repair restrictions, measuring system principles, and OEM/I-CAR documentation requirements. Questions are aligned to I-CAR ProLevel structural knowledge areas and ASE B3/B4 exam content; students must achieve 80% or higher to pass. Standard met · Safety · Time · Quality/finish · Documentation
Frame Straightening Skills Demonstration	Skills demonstration	45%	80% overall on the scored rubric; 100% on all safety-critical items	Each student sets up a frame bench, anchors a designated vehicle, performs a multi-pull repair sequence with continuous measurement monitoring, and presents a final post-repair measurement printout showing all control points within OEM tolerances. The instructor scores bench setup, anchor technique, pull planning, measurement monitoring, and corrosion protection using a rubric; all LOTO and PPE items are pass/fail at 100%. Standard met · Safety · Time · Quality/finish · Documentation
Lab Log	Log	15%	Minimum 10 of 12 lessons documented with complete entries; average score 80% on entry quality rubric	Students maintain a lab log throughout the course, recording learning objectives, procedures followed, measurement data, material specifications used, safety procedures applied, and personal reflections for each lesson. Logs are reviewed twice during the course by the instructor and evaluated at course end for completeness, accuracy of technical entries, and evidence of critical thinking about repair decisions. Standard met · Safety · Time · Quality/finish · Documentation
Safety Compliance Check	Safety audit	15%	100% — any critical failure requires immediate remediation and re-check before the student may continue frame lab work	A formal, unannounced safety audit conducted by the instructor at any point during lab operations; the checklist covers correct PPE worn for the task, proper LOTO applied to hydraulic and pneumatic equipment, safe anchoring of the vehicle before any pulling load, correct storage of chains and hooks, and SDS accessibility for all chemicals in use. Every item on the checklist is pass/fail; the student must achieve 100% compliance. Standard met · Safety · Time · Quality/finish · Documentation

TRN-AUTO25-03 Trade course

Panel Repair and Replacement

205 hr · ~~$2,950~~ COMPLIMENTARY

Students develop hands-on competency in diagnosing, repairing, and replacing exterior body panels using industry-standard hand tools, power tools, and panel-pulling equipment. Work covers metal straightening, plastic and composite repair, adhesive and mechanical fastener methods, and corrosion protection restored to pre-accident condition. Lessons align with I-CAR ProLevel non-structural damage and repair courses and ASE B2 (Non-Structural Analysis and Damage Repair) exam content areas.

Outcomes

Diagnose panel damage using visual inspection and measuring tools, selecting repair versus replacement based on cost, damage severity, and OEM repair guidelines.
Straighten steel and aluminum panels to within manufacturer tolerances using body hammers, dollies, slapping files, and stud-welding dent-pulling systems.
Repair rigid, semi-rigid, and flexible plastic substrates by selecting the correct adhesive or weld filler system and restoring structural integrity.
Remove and install bolt-on and structural bonded panels following OEM sequences, applying corrosion protection at all bare-metal and seam areas.
Apply body filler, glaze, and block-sand surfaces to a substrate profile ready for primer, verifying straightness with a straightedge and guide coat.
Demonstrate safe material handling, PPE selection, and shop hygiene practices compliant with OSHA standards throughout all panel repair operations.

Course text

How the course runs. 12 blocks: Damage Analysis and Repair Planning; Hand Tool Fundamentals: Hammers, Dollies, and Spoons; Stud Welding and Slide-Hammer Dent Pulling; Aluminum Panel Repair Techniques; Plastic and Composite Panel Identification and Repair; Bolt-On Panel Removal and Installation; Panel Bonding and Adhesive Installation; Corrosion Protection and Anti-Corrosion Materials; Body Filler: Mixing, Application, and Rough Shaping; Glaze, Block Sanding, and Substrate Finishing; Panel Edge Work, Door Skins, and Full Replacement Sequence; Panel Repair Capstone Integration and Final Evaluation.

What competent looks like. Diagnose panel damage using visual inspection and measuring tools, selecting repair versus replacement based on cost, damage severity, and OEM repair guidelines. Straighten steel and aluminum panels to within manufacturer tolerances using body hammers, dollies, slapping files, and stud-welding dent-pulling systems. Repair rigid, semi-rigid, and flexible plastic substrates by selecting the correct adhesive or weld filler system and restoring structural integrity. Remove and install bolt-on and structural bonded panels following OEM sequences, applying corrosion protection at all bare-metal and seam areas. Apply body filler, glaze, and block-sand surfaces to a substrate profile ready for primer, verifying straightness with a straightedge and guide coat. Demonstrate safe material handling, PPE selection, and shop hygiene practices compliant with OSHA standards throughout all panel repair operations.

Lessons · 12 blocks

#	Lesson	Hr	Type	Objective	Activities	Materials	Check
1	Damage Analysis and Repair Planning	13	theory	Students will identify primary, secondary, and indirect damage on a collision-damaged vehicle and document a written repair plan that justifies repair versus replace decisions using OEM and I-CAR guidelines.	Lecture and slideshow: damage terminology (direct, indirect, adjacent, stress), repair-vs-replace decision tree, and introduction to OEM repair information portals such as OEM1Stop or manufacturer sites. Hands-on walkthrough of two damaged vehicles in the shop: students use inspection lights, painter's tape, and a body measuring tape to map all damaged areas on a printed panel diagram. Written exercise: students draft a one-page repair plan for each vehicle, listing each damaged panel, estimated damage severity, and repair method, then compare plans in a group debrief.	Collision-damaged training vehicles (minimum 2), inspection flashlights, measuring tape, straightedges, printed vehicle panel diagrams, dry-erase markers, I-CAR Structural course reference materials, OEM repair information access (shop computer or tablet)	Completed written repair plan correctly identifies all instructor-seeded damage points (minimum 80% accuracy) and includes a justified repair-vs-replace recommendation for each panel; instructor sign-off required.
2	Hand Tool Fundamentals: Hammers, Dollies, and Spoons	16.5	demo	Students will correctly select and apply body hammers, dollies, and spoons to work steel panel damage using hammer-on and hammer-off dolly techniques without adding new distortion.	Instructor demonstration on a steel hood skin: hammer-on and hammer-off dolly techniques, pick hammer use for shrinking high spots, and spoon leverage for indirect damage access. Students practice hammer-on and hammer-off techniques on pre-dented 20-gauge steel practice panels clamped in a panel vise, cycling through at least four hammer/dolly combinations. Peer-check exercise: students use a metal straightedge and guide coat (light spray of dark aerosol primer) to reveal remaining highs and lows, then continue working until the guide coat is cut evenly.	Body hammers (picking, finishing, bumping), dollies (heel, toe, comma, general-purpose), body spoons, 20-gauge steel practice panels, panel vise or metal stand, metal straightedge, guide-coat spray, safety glasses, gloves	Practice panel surface is within 1.5 mm of flat verified by straightedge; no new distortion introduced; instructor observes correct grip, stance, and blow force before signing off.
3	Stud Welding and Slide-Hammer Dent Pulling	14.5	lab	Students will set up and operate a stud-welding dent-pulling system to extract panel damage from the outer surface without requiring backside access, then grind and clean studs to bare metal.	Instructor setup demo: ground connection placement, stud gun settings for steel gauge, single-pull and multi-stud serpentine sequence technique on a door skin. Students pull a minimum of three distinct dent scenarios (shallow wide dent, sharp crease, edge ding) on practice panels, documenting stud placement pattern and pull sequence in a lab log. After pulling, students grind stud remnants flush using a die grinder with a grinding stone, then clean with wax-and-grease remover and inspect with guide coat to verify final profile.	Stud-welding dent-pull kit, slide hammer, cross-bar puller, die grinder, grinding stones, wax-and-grease remover, tack cloths, guide-coat spray, 20-gauge and 18-gauge steel practice panels, angle grinder with flap disc, PPE: face shield, gloves, leather apron	Lab log completed for all three pulls; final panel profile within 1.5 mm of flat confirmed by guide coat; no burn-through or added distortion; PPE worn throughout — observed by instructor.
4	Aluminum Panel Repair Techniques	14.5	demo	Students will apply aluminum-specific work-hardening awareness and dedicated (non-cross-contaminated) tooling to straighten aluminum panels, and explain why aluminum cannot share steel repair tools.	Lecture: aluminum metallurgy basics — work hardening, annealing, and grain structure differences from steel; why galvanic corrosion occurs when steel tools contact aluminum. Instructor demonstration on an aluminum hood or fender: use of aluminum-dedicated hammers and dollies, heat application with a heat gun and temperature-indicating crayons, shrinking techniques. Students practice on aluminum practice panels using marked (red-tagged) dedicated aluminum tools only; any student reaching for a steel tool stops the drill and explains the contamination risk to the group.	Aluminum-dedicated body hammers and dollies (red-tagged), heat gun, temperature-indicating crayons (Tempilstik), aluminum practice panels, dedicated aluminum stud-weld kit (if applicable), wax-and-grease remover, PPE: safety glasses, heat-resistant gloves	Student correctly selects and uses only red-tagged aluminum tools without prompting; panel repaired to within 2 mm of flat; student verbally explains work-hardening and contamination risks — instructor verifies both.
5	Plastic and Composite Panel Identification and Repair	16.5	lab	Students will identify plastic substrate type using the burn test or embossed symbol, then repair a torn and gouged plastic bumper fascia to structural integrity using the appropriate adhesive or plastic welding method.	Identification exercise: students test six unlabeled plastic sample coupons using the burn test (in a ventilated fume hood) and compare flame, smoke, and odor to a reference chart; record substrate type. Adhesive repair lab: students prepare and repair a torn PP bumper fascia using a two-part urethane adhesive system — cleaning, abrading, applying backing strip, mixing and applying adhesive, clamping, and finish-sanding. Hot-air plastic welding demo and practice: students weld a crack in an ABS substrate using a hot-air welder with appropriate filler rod, then grind and sand the weld to a smooth profile.	Plastic identification chart, sample plastic coupons (PP, TPO, ABS, SMC, fiberglass), fume hood or ventilated area, hot-air plastic welder, plastic filler rods (PP, ABS), two-part urethane adhesive system, backing tape/strip, sandpaper (80–180 grit), sanding blocks, PPE: respirator (organic vapor), safety glasses, gloves	Identification chart completed with correct substrate for minimum five of six samples; repaired fascia passes flex test (no crack re-opening under hand flex); weld ground smooth within 0.5 mm of substrate — instructor evaluates each.
6	Bolt-On Panel Removal and Installation	16.5	practice	Students will remove and reinstall a bolt-on fender and door following OEM torque sequences, verifying panel gaps and flushness are within manufacturer specification using a gap gauge.	OEM documentation exercise: students locate the removal/installation procedure and torque specs for the assigned vehicle model using the shop's OEM information portal and print or annotate the relevant pages. Removal lab: students remove a fender and front door completely, labeling and bagging all fasteners by location, photographing alignment reference marks before removal. Reinstallation and alignment: students reinstall both panels, adjust mounting slots to match pre-removal photos, torque fasteners to spec using a torque wrench, and measure all gaps with a gap gauge — target within ±1 mm of OEM spec.	Training vehicle with accessible bolt-on fender and door, OEM repair information access, metric and SAE socket sets, torque wrench, door alignment bars, gap gauges, labeled zip-lock bags, camera or smartphone for reference photos, permanent marker	All gaps measured and recorded; gaps within ±1.5 mm of OEM specification at three measuring points per panel; torque wrench used on all fasteners — instructor verifies measurements and torque use.
7	Panel Bonding and Adhesive Installation	14.5	lab	Students will prepare mating surfaces and install a quarter-panel skin using a structural two-part panel bonding adhesive following OEM application procedures, achieving full coverage without voids.	Surface prep demonstration: grinding bonding flanges to bare metal with a grinder and rotary file, cleaning with wax-and-grease remover, scuffing with abrasive pad, applying bonding primer where required by OEM. Adhesive application practice on mock-up flanges: students mix and apply panel bonding adhesive from a cartridge gun, practice bead size and spacing, then press halves together and inspect squeeze-out for full coverage. Full quarter-panel skin bond-on on a training vehicle: students prep, apply, clamp, allow cure per product data sheet, then remove clamps and visually and tap-test the bond line for voids.	Training vehicle quarter panel or door skin, two-part panel bonding adhesive with cartridge gun and mixing nozzles, wax-and-grease remover, scuff pads, bonding primer, angle grinder, rotary file bits, C-clamps or panel clamps, product data sheet for adhesive, PPE: nitrile gloves, safety glasses, respirator	Squeeze-out visible around 90% of bond perimeter confirming coverage; tap test reveals no hollow voids; student demonstrates correct cartridge purge and mixing nozzle change procedure — instructor evaluates all three criteria.
8	Corrosion Protection and Anti-Corrosion Materials	13	theory	Students will select and apply the correct anti-corrosion material (weld-through primer, seam sealer, cavity wax, self-etch primer) for each panel joint and substrate type, explaining the purpose of each product.	Lecture and product comparison: weld-through primer (used before welding), seam sealer (exposed flanges), cavity wax (enclosed sections), self-etch primer (bare metal), epoxy primer (superior adhesion base) — when and why each is used. Hands-on application stations: students rotate through five stations and apply each product on labeled metal coupons following product data sheet instructions, then photograph and annotate results. Case study analysis: instructor presents two failure examples (a rusted repaired panel and a blistered finish over bare metal) and students diagnose which corrosion protection step was skipped, presenting findings to the group.	Weld-through primer, seam sealer (brushable and gun-applied), cavity wax with injection nozzle, self-etch primer, epoxy primer aerosol, steel coupons, application brushes, seam sealer gun, product data sheets for each product, PPE: respirator, nitrile gloves, safety glasses	Written station worksheet correctly matches each product to its application scenario and substrate for all five stations (minimum 80% correct); application on coupons evaluated for correct film build — instructor signs.
9	Body Filler: Mixing, Application, and Rough Shaping	18	practice	Students will mix polyester body filler to the correct hardener ratio, apply it to a steel panel in controlled coats, and rough-shape using a cheese-grater file and 80-grit sandpaper before filler cures fully.	Mixing drill: students mix five practice batches of filler on a spreader board, varying hardener ratio (correct, over-catalyzed, under-catalyzed), observe cure time and color streaking, and record observations in a lab log. Application practice: students apply correctly mixed filler to a prepared dented practice panel in two coats, keeping each coat under 6 mm; immediately shape with a body file (cheese grater) while still green. Block sanding: students block-sand with 80-grit, apply guide coat, and continue until guide coat is fully cut, indicating a flat surface; they then finish with 150-grit for a smooth substrate profile.	Polyester body filler, cream hardener, plastic mixing boards and spreaders, body file (cheese-grater Surform), DA sander with 80-grit and 150-grit discs, sanding blocks, guide-coat spray, wax-and-grease remover, PPE: dust respirator (P100), safety glasses, gloves	Panel surface within 1 mm of flat confirmed by metal straightedge and fully cut guide coat; no pinholes visible at 150-grit stage; lab log shows correct hardener ratio identified — instructor verifies all three.
10	Glaze, Block Sanding, and Substrate Finishing	16.5	practice	Students will apply polyester spot putty or glaze coat to fill pinholes and low spots, then block-sand through a progressive grit sequence to produce a substrate profile ready for primer-surfacer.	Lecture and demo: difference between body filler and glaze coat — filler builds, glaze fills pinholes only; application technique for thin skim coats; grit sequence logic (80 → 150 → 180 → 220). Students apply glaze over their lesson 9 panels, focusing only on pinhole and low-spot areas; allow cure and block-sand with a flexible block through 150 and 180 grit, using guide coat at each step. Final straightness check: students use a long metal straightedge (600 mm) and feeler gauge across the panel in multiple directions; any deviation greater than 1.5 mm requires additional work before the panel is signed off.	Polyester glaze coat / spot putty, plastic spreaders, dual-action (DA) sander, sanding blocks (flexible and rigid), sandpaper 80–220 grit, guide-coat spray, metal straightedge (600 mm), feeler gauges, wax-and-grease remover, PPE: dust respirator, safety glasses	No pinholes visible under raking light at 220-grit; feeler gauge confirms flatness within 1.5 mm across full panel; student demonstrates correct block-sanding grip and stroke — instructor evaluates under raking light.
11	Panel Edge Work, Door Skins, and Full Replacement Sequence	27.5	lab	Students will complete a full door skin replacement sequence — stripping the old skin, installing a new skin with hem folding or bonding, applying all corrosion protection, and finishing the repair to a primer-ready substrate.	Hem-flange cutting and stripping: students use a pneumatic chisel and spot-weld drill to remove a damaged door skin from a practice door shell without damaging the inner structure, cleaning all flanges after removal. New skin installation: students fit the replacement skin, apply panel bonding adhesive at flanges, fold the hem with a hem-folding tool or hammer-and-dolly, apply seam sealer to all exposed edges, and allow cure. Finishing sequence: students apply weld-through primer and seam sealer to the inner hem, then work the outer surface through body filler, glaze, and 180-grit blocking to a primer-ready finish — photographed and documented in the lab log.	Practice door shell with damaged skin, replacement door skin, pneumatic chisel, spot-weld drill set, hem folding tool, panel bonding adhesive, seam sealer, weld-through primer, body filler, glaze, sanding supplies (80–180 grit), seam sealer gun, corrosion-protection products, camera, lab log, PPE: face shield, leather apron, gloves, dust respirator	Lab log documents every stage with photos; hem is fully seated with no gaps greater than 1 mm; seam sealer covers all exposed metal edges; substrate is flat within 1.5 mm at 180-grit — instructor signs off on log and physical panel.
12	Panel Repair Capstone Integration and Final Evaluation	24	lab	Students will independently complete a multi-panel repair assignment — diagnosing, straightening, filling, and finishing two adjacent damaged panels to a primer-ready substrate — demonstrating all course skills without instructor prompting.	Day 1 (planning): students receive a vehicle or mock-up with instructor-seeded damage on two adjacent panels, write a full repair plan including method selection, corrosion protection plan, and material list, then submit for review before starting. Days 2–4 (repair execution): students execute the full repair sequence independently — metal work, plastic or filler repair as appropriate, corrosion protection, body filler, glaze, and block sanding to 180-grit guide-coat check. Day 5 (evaluation and debrief): instructor conducts a walk-around evaluation using a standardized rubric; student presents their lab log, explains each decision made, and receives written feedback.	Training vehicle or multi-panel mock-up with two damaged areas, full shop tool inventory (hammers, dollies, stud-pull kit, DA sander, body filler, glaze, sandpaper, corrosion products), gap gauges, metal straightedge, guide coat, lab log template, evaluation rubric, PPE: all applicable per operation	Rubric score of 75% or higher across all categories: metal work quality, filler application, surface flatness (straightedge and guide coat), corrosion protection completeness, lab log accuracy, and safety compliance throughout — any PPE violation results in automatic re-do.

Assessments

Assessment	Type	Weight	Pass standard	Method & rubric
Panel Repair Knowledge Exam	Written exam	25%	75% or higher (30 of 40 questions correct)	A 40-question written exam covering damage analysis and repair-vs-replace criteria, plastic substrate identification, corrosion protection product selection, body filler hardener ratios, and bolt-on panel alignment procedures, mapped to ASE B2 and I-CAR non-structural damage content areas. Students have 60 minutes; multiple choice and short-answer formats. Standard met · Safety · Time · Quality/finish · Documentation
Panel Straightening and Finishing Skills Demonstration	Skills demonstration	45%	Panel surface within 1.5 mm of flat at all measurement points; guide coat fully cut at 180-grit; all corrosion protection applied; no PPE violations observed	Instructor assigns a steel panel with three seeded defects (one dent, one crease, one high spot); student straightens, applies filler, and blocks to a primer-ready finish within a four-hour timed session. Instructor evaluates using a standardized rubric covering metal work, filler technique, surface profile, and corrosion protection. Standard met · Safety · Time · Quality/finish · Documentation
Lab Log Portfolio	Log	15%	Minimum 80% of required entries present, complete, and accurately describe the operation performed; all photo evidence included	Students submit the cumulative lab log maintained across lessons 3, 5, 7, 9, 10, and 11, showing written descriptions, annotated photographs, material product data sheet references, and self-assessments for each lab. Instructor evaluates completeness, technical accuracy, and reflection quality using a scoring rubric. Standard met · Safety · Time · Quality/finish · Documentation
Safety and Hazmat Compliance Check	Safety audit	15%	Pass — all critical items correct; any critical failure (missing PPE, incorrect SDS identification, improper waste disposal) requires immediate remediation and recheck before student may continue lab work	Unannounced practical safety audit conducted during a lab session: instructor observes PPE selection and use, verifies the student can locate and read the SDS for three products in use, checks that flammable waste rags are stored in an approved closed container, and confirms the student can describe the lockout/tagout step required before any corrosion protection spray operation in an enclosed panel area. Standard met · Safety · Time · Quality/finish · Documentation

TRN-AUTO25-04 Trade course

Welding for Auto Body & Collision Repair

204 hr · ~~$2,940~~ COMPLIMENTARY

This course develops the welding knowledge and hands-on skills required for structural and cosmetic collision repair, covering MIG (GMAW), resistance spot welding, and plasma cutting as specified by OEM repair procedures and I-CAR welding standards. Students learn to select the correct process, set up equipment safely, and produce welds that meet tensile and visual quality criteria on automotive-grade steels including high-strength and ultra-high-strength steel (HSS/UHSS). Lessons map directly to I-CAR ProLevel welding competencies and ASE B-series structural analysis and damage repair content.

Outcomes

Set up and operate a MIG welder to produce plug, butt, and lap welds on mild steel, HSS, and aluminum panels that pass visual and destructive pull-test inspection.
Perform resistance spot welding using OEM-specified spacing and nugget-size standards on multi-layer automotive assemblies.
Execute plasma arc cuts and angle-grinder metal preparation that meet dimensional tolerances for panel replacement joints.
Identify and correct common weld defects—porosity, undercut, incomplete fusion, and burn-through—using OEM repair procedure references.
Apply all required PPE and ventilation controls, demonstrate fire-watch procedures, and complete a lockout/tagout sequence on welding equipment before service.
Document weld locations, process selections, and heat-management steps on a repair order in compliance with I-CAR ProLevel recordkeeping expectations.

Course text

How the course runs. 12 blocks: Welding Safety, Hazard Controls, and Shop Setup; Metals Used in Modern Vehicles: Properties and Weldability; MIG Welder Anatomy, Setup, and Machine Settings; MIG Plug and Lap Welds on Mild Steel; MIG Butt Welds and Panel Sectioning Joints; Welding High-Strength and Ultra-High-Strength Steel; Resistance Spot Welding: Equipment and Technique; Plasma Arc Cutting and Grinding Preparation; Weld Defect Identification and Correction; Aluminum MIG Welding: Introduction and Panel Repair; OEM Repair Procedures and Documentation for Welded Repairs; Integrated Welding Practical: Structural Panel Section and Documentation.

What competent looks like. Set up and operate a MIG welder to produce plug, butt, and lap welds on mild steel, HSS, and aluminum panels that pass visual and destructive pull-test inspection. Perform resistance spot welding using OEM-specified spacing and nugget-size standards on multi-layer automotive assemblies. Execute plasma arc cuts and angle-grinder metal preparation that meet dimensional tolerances for panel replacement joints. Identify and correct common weld defects—porosity, undercut, incomplete fusion, and burn-through—using OEM repair procedure references. Apply all required PPE and ventilation controls, demonstrate fire-watch procedures, and complete a lockout/tagout sequence on welding equipment before service. Document weld locations, process selections, and heat-management steps on a repair order in compliance with I-CAR ProLevel recordkeeping expectations.

Lessons · 12 blocks

#	Lesson	Hr	Type	Objective	Activities	Materials	Check
1	Welding Safety, Hazard Controls, and Shop Setup	14	theory	Students will identify all welding-related hazards in a collision shop and correctly select PPE, ventilation, and fire-prevention measures before any welding operation begins.	Instructor-led walkthrough of the welding bay: students label each hazard (UV/IR arc flash, fumes, compressed gas, electrical, fire) on a shop diagram and match it to the correct OSHA 29 CFR 1910 Subpart Q or 1926 Subpart J control measure. Students practice donning and doffing full welding PPE kit—auto-darkening helmet, leather gloves, flame-resistant jacket, respirator—and complete a PPE inspection checklist, identifying two intentionally defective items placed by the instructor. Lockout/tagout exercise: students follow a written LOTO procedure to de-energize a MIG welder and verify zero-energy state with a voltmeter before a simulated blade change, then re-energize and document each step on a LOTO log sheet.	Auto-darkening welding helmet (ANSI Z87.1), leather welding gloves, FR jacket, half-face respirator with OV/P100 cartridges, OSHA welding safety poster, voltmeter, shop LOTO station, I-CAR Welding Study Guide, OSHA 29 CFR 1910 Subpart Q reference printout	Written 20-question safety quiz scored at 80% or higher; LOTO demonstration observed by instructor with zero missed steps required to pass.
2	Metals Used in Modern Vehicles: Properties and Weldability	12	theory	Students will classify a vehicle steel sample as mild, HSS, AHSS, or UHSS using a reference chart and state the correct welding process limitations for each grade.	Lecture and I-CAR reference chart review: students sort a set of labeled steel coupons (mild, DP590, UHSS boron steel, aluminum 5xxx series) into a classification matrix and explain why UHSS must never be heat-straightened. Students read two OEM body repair manuals (generic instructor-selected examples) and highlight welding process restrictions for a B-pillar repair section, then compare findings with a partner. Short answer worksheet: students match five vehicle zones (bumper beam, rocker, roof rail, quarter panel, hood skin) to their typical steel grade and write the maximum preheat or heat restriction for each.	Labeled steel coupon set, I-CAR Steel and Aluminum Fundamentals reference, OEM structural repair section printouts (two makes), metal identification chart, whiteboard	Coupon classification exercise scored at 80% accuracy; short-answer worksheet reviewed and corrected in class before next lesson.
3	MIG Welder Anatomy, Setup, and Machine Settings	14	demo	Students will set wire feed speed, voltage, and shielding gas flow rate on a MIG welder to within the acceptable range for a given steel thickness using a settings chart.	Instructor demonstrates component identification—wire spool, drive rolls, liner, contact tip, nozzle, ground clamp—while students complete a labeled diagram handout, then install and tension a fresh 0.030 in. ER70S-6 wire spool under supervision. Using a manufacturer settings chart and steel coupons of three thicknesses (18 ga, 16 ga, 3/16 in.), students adjust voltage and wire feed speed in pairs, record each setting on a log sheet, and run a short bead on scrap to verify the setting before moving on. Students check and set shielding gas flow rate to the recommended range with a flowmeter, purge the gun, and inspect the contact tip and nozzle for spatter buildup, replacing one intentionally worn tip provided by the instructor.	MIG welders (Lincoln Electric or equivalent), 0.030 in. ER70S-6 wire spools, C25 shielding gas cylinders with regulators and flowmeters, contact tips, nozzles, drive rolls, settings chart, steel coupons (18 ga / 16 ga / 3/16 in. mild steel), labeled diagram handout	Instructor observes each student independently set machine for a specified coupon thickness; settings must fall within manufacturer's recommended range and the student must verbally state the rationale—pass requires both correct setting and correct explanation.
4	MIG Plug and Lap Welds on Mild Steel	20	lab	Students will produce MIG plug welds and lap welds on 18-gauge mild steel coupons that pass both visual inspection and a destructive peel-back test showing full nugget fusion.	Instructor demonstrates plug-weld hole drilling (5/16 in. diameter), clamping technique, and correct gun angle (5–15° travel angle), then welds a sample panel while narrating each step; students sketch the setup. Students drill plug-weld holes, clamp a two-layer 18-gauge coupon set, and produce a row of ten plug welds, then grind flush and perform a visual inspection against the I-CAR visual weld quality standards checklist. Students perform a destructive peel-back test using pliers and a hammer on a lap-weld coupon: the weld nugget must remain in one panel (base-metal failure), not peel cleanly at the interface; results are recorded on the lab log with pass/fail notation.	MIG welders, 18-ga mild steel coupons (pre-cut 3 in. × 6 in.), 5/16 in. drill bits and drill press, C-clamps, angle grinder with flap disc, pry bar, hammer, I-CAR Welding Quality Standards reference card, lab log forms	Ten plug welds visually inspected—no more than one weld may show porosity, undercut, or incomplete fill to pass; destructive test on two lap-weld coupons must both show base-metal failure, not interface separation.
5	MIG Butt Welds and Panel Sectioning Joints	20	lab	Students will fit and MIG-weld a butt joint on 18-gauge steel with a gap of 1/16 in. or less and produce a weld bead that passes visual inspection and remains intact after a 90-degree bend test.	Instructor demonstrates panel sectioning layout using a body saw and cut-off wheel, emphasizing location selection away from factory welds and factory-reinforced zones, per I-CAR sectioning guidelines; students mark a practice panel. Students cut two 18-gauge panels, fit them in a fixture with correct gap, tack at each end and midpoint, then complete a continuous butt weld using stitch technique to manage heat distortion; instructor monitors heat and gun travel. Students perform a 90-degree guided bend test by clamping the welded coupon in a vise and bending with a hammer over a mandrel; the weld must show no cracking to pass, and results are photographed and entered in the lab log.	MIG welders, 18-ga mild steel panels, body saw, cut-off wheel and angle grinder, welding fixture or magnetic clamps, vise, bend-test mandrel (1T radius), camera or smartphone for documentation, lab log forms, I-CAR Sectioning Guidelines reference	Visual inspection of completed butt weld against I-CAR checklist (no undercut exceeding 10% of base thickness, no porosity visible, consistent bead width); bend test must show zero cracks across the weld—both criteria required to pass.
6	Welding High-Strength and Ultra-High-Strength Steel	16	demo	Students will state the process and heat-input restrictions for welding HSS and UHSS and correctly set up a MIG welder for a DP590 coupon following OEM reference guidance.	Instructor-led comparison demo: weld DP590 coupon with correct settings, then weld a second coupon with excessive heat; students measure distortion and inspect heat-affected zone (HAZ) width with a ruler to observe difference in degradation. Students review an OEM repair procedure for a structural rail section made from UHSS and write a one-paragraph repair plan identifying: process permitted, heat restrictions, sectioning location, and filler wire specification. Students set up the MIG welder for a DP590 coupon using the settings chart and weld two plug welds; instructor performs a live peel-back test in front of the class and the group evaluates the result against the quality standard.	MIG welders, DP590 coupons (18 ga), ER70S-6 wire, OEM structural repair procedure printout, ruler and temperature-indicating sticks (tempilstik) or infrared thermometer, I-CAR Steel Fundamentals reference, lab log forms	Students verbally answer three instructor questions about HSS/UHSS heat restrictions with 100% accuracy; plug-weld peel-back test on DP590 coupon shows base-metal failure to pass the demo—no written exam, but lab log entry required.
7	Resistance Spot Welding: Equipment and Technique	18	lab	Students will produce resistance spot welds on two-layer 18-gauge steel that meet OEM nugget size and spacing specifications and pass a destructive peel test.	Instructor demonstrates resistance spot welder setup: electrode tip dressing, electrode force setting, weld-time selection, and coupon clamping; students dress a set of tips using a tip dresser and record tip condition before and after. Students produce a row of spot welds on clamped two-layer coupons, spacing welds to match a provided OEM spacing template (typically 1–1.5 in. spacing depending on gauge), then mark each weld location on a diagram. Destructive peel-back test: students separate the two layers with a chisel and hammer; each nugget is measured with calipers and must meet or exceed the minimum nugget diameter specified on the OEM reference (expressed as a formula or table range) to pass.	Resistance spot welder (squeeze-type or portable), electrode tip dresser, 18-ga mild steel coupons, OEM spot-weld spacing template, chisel, hammer, digital calipers, lab log forms, I-CAR Resistance Spot Welding reference	Eight of ten spot welds per student must produce nuggets meeting minimum diameter on peel-back test; spacing must be within ±1/8 in. of template—both criteria required for pass.
8	Plasma Arc Cutting and Grinding Preparation	14	lab	Students will make a plasma arc cut along a scribed line on 18-gauge steel to within 1/8 in. of the line and prepare the cut edge to a smooth, square profile using an angle grinder.	Instructor demonstrates plasma cutter setup—air pressure setting, consumable inspection, standoff distance, and travel speed—then cuts a panel while narrating; students check plasma consumables on their unit against a new-consumable reference photo. Students scribe a straight cut line on an 18-gauge panel, set plasma cutter to the recommended amperage for that thickness, and make the cut wearing full PPE; the cut is measured against the scribed line with a straightedge. Students use a 36-grit flap disc and then a 120-grit disc to dress the cut edge square and smooth, final-checking flatness with a metal straightedge and recording the preparation steps on the lab log.	Plasma cutter with air compressor (minimum 4 CFM at rated pressure), plasma consumables (tip, electrode, shield), 18-ga mild steel panels, scriber, straightedge, ruler, angle grinder with 36-grit and 120-grit flap discs, full PPE, lab log forms	Cut must remain within 1/8 in. of scribed line for full length; edge preparation inspected by instructor—no rolled edge, sharp burrs, or surface scale remaining—both pass.
9	Weld Defect Identification and Correction	14	theory	Students will identify six common MIG weld defects from physical specimens and photographs and prescribe the correct machine or technique adjustment to eliminate each defect.	Instructor presents a defect specimen board with labeled examples of porosity, undercut, overlap, burn-through, incomplete fusion, and excessive spatter; students match each specimen to its cause using a cause-and-effect chart. Students examine five unlabeled defect weld coupons, write the defect name and probable cause on a worksheet, then share findings with the class for instructor correction and discussion. Students intentionally produce one defect weld (instructor assigns the defect type), photograph it, diagnose the setting error, correct the machine or technique, and re-weld a passing coupon; both coupons and the written diagnosis are submitted in the lab log.	Defect specimen board (pre-made by instructor), defect photograph reference sheet, MIG welders, 18-ga mild steel coupons, cause-and-effect chart, camera or smartphone, lab log forms, I-CAR Weld Quality Standards reference	Worksheet scored at 80% or higher on defect identification and cause; corrected re-weld coupon must pass visual inspection using I-CAR quality checklist to complete the lab.
10	Aluminum MIG Welding: Introduction and Panel Repair	18	lab	Students will convert a MIG welder to aluminum setup, produce a plug weld on 5052 aluminum sheet, and explain why aluminum requires different shielding gas, wire, and technique compared to steel.	Instructor demonstrates aluminum setup: dedicated spool gun or Teflon liner, 0.035 in. ER4043 wire, 100% argon shielding gas, push technique (not drag); students convert a MIG welder under supervision following a written checklist. Students clean 5052-H32 aluminum coupons with a dedicated stainless steel brush and acetone wipe (in sequence: solvent first, brush second), then drill plug holes and produce five plug welds using the push technique. Students inspect aluminum plug welds against an aluminum-specific visual criteria card (checking for black soot indicating contamination, burn-through due to high conductivity, and consistent bead profile), record results, and cross-contamination prevention steps in the lab log.	MIG welder with spool gun or Teflon liner, 0.035 in. ER4043 wire, 100% argon cylinders with regulator, 5052-H32 aluminum coupons, dedicated stainless steel brush (aluminum-only labeled), acetone, nitrile gloves, aluminum visual criteria card, lab log forms	Instructor observes correct setup sequence with zero cross-contamination errors; three of five plug welds must pass aluminum visual criteria card inspection to earn a pass on the lab.
11	OEM Repair Procedures and Documentation for Welded Repairs	14	theory	Students will locate weld specifications in an OEM repair procedure for an assigned vehicle model and complete a repair order documenting process selection, joint type, and heat management steps.	Students access OEM repair information through an instructor-provided portal (e.g., a demo account on a recognized OEM information platform) and locate the structural repair section for an assigned year/make/model, identifying weld type, number of welds, and any prohibited operations. Students complete a sample repair order form for a quarter-panel replacement, listing: OEM weld specifications, steel grade, shielding gas type, wire size, and post-weld corrosion protection steps required by the OEM procedure. Pairs of students swap completed repair orders and peer-review for missing or incorrect information using an instructor-supplied checklist, then present one finding each to the class.	Computers or tablets with OEM repair information portal access, sample repair order forms (blank), peer-review checklist, I-CAR ProLevel documentation reference, whiteboard	Completed repair order reviewed by instructor: must include all eight required fields (OEM source, steel grade, joint type, process, wire spec, gas spec, weld quantity/location, corrosion protection step) with no more than one field missing or incorrect to pass.
12	Integrated Welding Practical: Structural Panel Section and Documentation	30	lab	Students will plan and execute a complete sectioning and replacement weld on a door skin or quarter-panel section using correct MIG or resistance spot welding processes, producing a repair order and passing all quality checks without instructor prompting.	Students receive a damaged panel assembly and an OEM repair procedure excerpt; they independently write a step-by-step repair plan including process selection, joint location, weld count, and corrosion protection, then review the plan with the instructor before beginning. Students execute the full repair—cut, fit, weld, grind flush, inspect, and apply weld-through primer to bare metal areas—documenting each step with photographs and entries in the lab log. Instructor conducts a structured walkthrough: student verbally defends process choices while instructor applies pull-test or visual inspection to the completed welds; student self-scores against the I-CAR quality checklist before the instructor scores independently.	Damaged panel assemblies (door skin or quarter-panel from salvage), MIG welders, resistance spot welder, plasma cutter, angle grinder, body saw, weld-through primer, full PPE, OEM repair procedure excerpt, repair order forms, digital camera or smartphone, I-CAR quality checklist, lab log forms	Repair order complete with all required fields; all welds pass I-CAR visual inspection checklist; pull or peel test passes on a minimum of two spot or plug welds per joint; student correctly answers three verbal defense questions—all four criteria must be met to pass.

Assessments

Assessment	Type	Weight	Pass standard	Method & rubric
Welding Theory Knowledge Exam	Written exam	25%	75% or higher (30 of 40 questions correct)	A 40-question written exam covering metal classification, MIG machine setup, shielding gas selection, weld defect identification, OEM procedure interpretation, and safety requirements; questions are drawn from I-CAR ProLevel welding content areas and ASE B-series structural knowledge domains. Students who score below 75% may re-take once after targeted remediation. Standard met · Safety · Time · Quality/finish · Documentation
MIG Welding Skills Demonstration	Skills demonstration	45%	All three weld types (plug, butt, lap) pass both visual inspection and destructive test; no weld may be re-done more than once during the assessment	The instructor assigns steel grade and thickness; the student independently sets up the MIG welder, selects wire and gas, and produces one plug weld, one butt weld, and one lap weld on the assigned material without coaching. Each weld is evaluated against the I-CAR visual quality standard and then subjected to a peel or bend test; students must also correctly state the process rationale before beginning. Standard met · Safety · Time · Quality/finish · Documentation
Welding Lab Log	Log	15%	Minimum of 10 of 12 lessons logged with complete entries; each entry must include date, process, settings, material, result, and corrective action if applicable	Students maintain a running lab log throughout the course, recording setup parameters, weld results, defect diagnoses, and documentation steps for every hands-on lesson. The completed log is reviewed at mid-course (after Lesson 6) and at course end; the end-of-course review checks completeness, accuracy of recorded settings against instructor records, and quality of self-assessment notes. Standard met · Safety · Time · Quality/finish · Documentation
Welding Area Safety Check	Safety audit	15%	Zero critical errors; a critical error is any missed PPE item, incorrect LOTO step, missing fire watch, or uncontrolled fume hazard—any single critical error is an automatic fail requiring full re-demonstration	Before beginning the final integrated practical (Lesson 12), an instructor evaluates each student against a 20-point safety checklist: PPE selection and condition, ventilation setup, gas cylinder securing, fire extinguisher accessibility, LOTO completion on any de-energized equipment, and housekeeping. Students who fail are removed from the lab, remediated, and must repeat the full safety check before participating. Standard met · Safety · Time · Quality/finish · Documentation

TRN-AUTO25-05 Trade course

Refinish: Surface Preparation, Mixing, and Paint Application

204 hr · ~~$2,940~~ COMPLIMENTARY

Students develop the complete refinishing skill set used in a production collision repair shop, from bare-metal surface preparation through color-matched basecoat/clearcoat application and final polishing. Lessons integrate safe handling of flammable and toxic materials under OSHA and EPA standards with the technical precision required for showroom-quality results. Outcomes map directly to ASE B-series Paint & Refinishing (B2) exam competencies and I-CAR Refinishing Group (REF) training standards.

Outcomes

Safely identify, store, and dispose of refinish chemicals in compliance with OSHA HazCom (SDS requirements) and applicable EPA VOC regulations.
Prepare substrates—bare metal, body filler, primer, and existing paint—to the surface profile required for adhesion of topcoat systems.
Mix waterborne and solvent-borne basecoat/clearcoat materials to manufacturer-specified ratios using a calibrated scale and viscosity cup.
Operate a conventional, HVLP, and LVLP spray gun to apply primer, sealer, basecoat, and clearcoat within acceptable film-build and appearance standards.
Perform color retrieval using a spectrophotometer and blend/spot-repair techniques to achieve a visually acceptable match under standard lighting.
Correct defects—orange peel, solvent pop, runs, sags, and dirt nibs—through compound, polish, and wet-sand procedures.

Course text

How the course runs. 12 blocks: Refinish Shop Safety: Hazard Communication, Ventilation, and PPE; Paint System Technology: Chemistry and Product Lines; Surface Preparation: Bare Metal and Existing Finishes; Body Filler and Spot Putty: Application and Block Sanding; Primer Systems: Selection, Application, and Blocking; Spray Gun Fundamentals: Setup, Adjustment, and Cleaning; Basecoat Application: Solid, Metallic, and Pearl Colors; Clearcoat Application and Blending; Color Theory and Spectrophotometer-Based Color Matching; Paint Defect Identification and Correction; Masking, Overspray Control, and Vehicle Protection; Final Refinish Quality Inspection and Documentation.

What competent looks like. Safely identify, store, and dispose of refinish chemicals in compliance with OSHA HazCom (SDS requirements) and applicable EPA VOC regulations. Prepare substrates—bare metal, body filler, primer, and existing paint—to the surface profile required for adhesion of topcoat systems. Mix waterborne and solvent-borne basecoat/clearcoat materials to manufacturer-specified ratios using a calibrated scale and viscosity cup. Operate a conventional, HVLP, and LVLP spray gun to apply primer, sealer, basecoat, and clearcoat within acceptable film-build and appearance standards. Perform color retrieval using a spectrophotometer and blend/spot-repair techniques to achieve a visually acceptable match under standard lighting. Correct defects—orange peel, solvent pop, runs, sags, and dirt nibs—through compound, polish, and wet-sand procedures.

Lessons · 12 blocks

#	Lesson	Hr	Type	Objective	Activities	Materials	Check
1	Refinish Shop Safety: Hazard Communication, Ventilation, and PPE	14	theory	Students will identify the specific chemical, fire, and respiratory hazards present in a refinish department and correctly apply OSHA HazCom SDS requirements, lockout/tagout for spray booth equipment, and the appropriate PPE for each task.	Read and annotate SDSs for three common refinish products (primer, basecoat, clearcoat hardener); locate flammability, exposure limits, and first-aid sections; summarize required PPE and disposal method in writing. Complete a guided shop walk identifying ventilation points, explosion-proof lighting fixtures, fire suppression locations, eyewash stations, and solvent waste containers; document findings on a provided checklist. Demonstrate donning and doffing a supplied-air respirator and a half-face APF-10 respirator with OV/P100 cartridges, inspect cartridges for service life, and perform a positive- and negative-pressure seal check observed by the instructor.	SDSs for representative primer, basecoat, and clearcoat products; OSHA HazCom 2012 poster; supplied-air and half-face respirators; OV/P100 cartridges; PPE inspection checklist; I-CAR REF01 reference guide; spray booth layout diagram	Written SDS quiz scoring 80% or higher on 20 questions covering flammability class, PEL/TLV identification, required PPE, and disposal; respirator seal check observed as pass/fail by instructor with no leakage detected.
2	Paint System Technology: Chemistry and Product Lines	12	theory	Students will classify lacquer, enamel, urethane, waterborne, and UV-cure refinish systems by chemistry, describe the role of each component (resin, pigment, solvent, catalyst), and explain how VOC regulations affect product selection.	Compare technical data sheets (TDS) for a solvent-borne and a waterborne basecoat from the same manufacturer; list differences in reducer selection, flash time, and application equipment cleaning procedure. Sort a set of 12 unlabeled product containers into system families (primer, sealer, basecoat, clearcoat, hardener, reducer) using color-coded TDS excerpts and justify each classification in a short written response. Group discussion: review how regional VOC regulations (g/L limits) affect which products a shop may stock; students draft a one-paragraph shop policy statement for a hypothetical collision center.	Technical data sheets from at least two paint manufacturers; I-CAR REF03 course material; EPA 40 CFR Part 63 Subpart HHHHHH plain-language summary; product comparison worksheet	Product-classification exercise scored by instructor; students must correctly categorize at least 10 of 12 samples and accurately describe VOC compliance implications for 3 of 3 scenario questions.
3	Surface Preparation: Bare Metal and Existing Finishes	20	lab	Students will prepare a steel panel with bare metal areas and existing paint to the surface profile and cleanliness required for primer adhesion, using abrasives, chemical cleaners, and blow-off procedures in the correct sequence.	Featheredge a 6-inch area of existing paint using a DA orbital sander with 80-, 180-, and 320-grit discs, verifying each step with a fingernail-edge test and confirming no lifted edges remain before proceeding. Remove wax, silicone, and road-film contamination from a test panel using a wax-and-grease remover applied with clean cloths in a two-cloth (wet/dry) wipe technique, then inspect under a black light for residual contamination. Sand bare-metal areas to 80-grit scratch profile to promote adhesion, blow off with compressed air, apply self-etching primer, and record ambient temperature, relative humidity, and dry time on a job card.	DA orbital sander; 80-, 180-, 320-, 400-grit abrasive discs and sheets; wax-and-grease remover; clean lint-free wiping cloths; self-etching primer; spray gun or aerosol; digital thermometer/hygrometer; black light; practice steel panels; I-CAR REF05 reference	Instructor evaluates featheredge using a fingertip test and raking light—no taper breaks or lifted edges; panel passes wax-free check under black light; job card completed with all environmental readings; 80% pass on all criteria using a 5-point rubric per criterion.
4	Body Filler and Spot Putty: Application and Block Sanding	16	lab	Students will mix, apply, and block-sand polyester body filler and spot putty on a practice panel so that the repaired area is within acceptable guide-coat scratch depth and flatness tolerances before primer application.	Mix polyester filler with hardener at the manufacturer's ratio using a mixing board, verifying color uniformity; apply with a spreader to a ding area and time the working period; mark any fish-eyes or voids before the material sets. Block-sand the cured filler using a guide coat and flat sanding block with 80- and then 180-grit paper, stopping to re-check with a straight edge and marking any low spots; re-apply and re-sand as needed until straight. Apply two-part glazing putty with a squeegee to remaining pinholes, let cure, and finish block-sand to 220 grit; photograph the panel before and after for the lab log.	Polyester body filler and hardener; mixing board and spreader; guide coat spray can or powder; flat sanding block; 80-, 120-, 180-, 220-grit sandpaper; two-part glazing putty; straight edge; digital caliper; camera or phone for documentation	Straight-edge measurement across repair shows no deviation greater than 1/16 inch over a 12-inch span; guide coat fully removed at 220 grit with no deep scratches visible; pinhole count under raking light equals zero; lab-log photographs submitted.
5	Primer Systems: Selection, Application, and Blocking	18	lab	Students will select an appropriate primer or primer-surfacer for the substrate, apply it to manufacturer-specified mil thickness, and block-sand it to a scratch-free surface ready for topcoats.	Use a wet-film gauge to measure primer film build during application on a practice panel, adjusting gun distance and speed until a consistent 1.5–2.0 mil wet film is achieved; calculate expected dry-film build using manufacturer solid-content data. Apply two-stage urethane primer-surfacer to a prepared panel—two medium coats with specified flash time between coats—recording temperature, humidity, and time on a job card; bake in the spray booth at the manufacturer's temperature. Block-sand cured primer with 320- and then 400-grit wet/dry paper on a foam block using guide coat; inspect under raking light until all guide coat is removed and surface is uniform; clean and tack wipe before topcoat.	Urethane primer-surfacer, hardener, and reducer; HVLP spray gun; wet-film gauge; dry-film thickness gauge (magnetic); foam sanding blocks; 320- and 400-grit wet/dry sandpaper; guide coat; tack cloths; spray booth; job card forms; manufacturer TDS	Dry-film thickness measured with gauge at five locations—all readings within manufacturer-specified range; no sand-through at edges; guide coat completely removed; job card fully completed; instructor rates surface texture with 80% pass on 5-point rubric.
6	Spray Gun Fundamentals: Setup, Adjustment, and Cleaning	16	demo	Students will set up, adjust, and clean a conventional, an HVLP, and an LVLP spray gun, demonstrating correct fluid tip size selection, air-cap atomization pressure, fan width, and fluid delivery for primer and basecoat materials.	Disassemble and identify every component of an HVLP gravity-feed gun; reassemble in correct order with instructor observing; torque fluid tip to manufacturer specification and confirm no air or fluid leaks at 29 PSI inlet pressure. Spray test patterns on masking paper, adjusting fan, fluid, and air knobs one at a time to correct a heavy center, heavy edges, and top/bottom split pattern defect shown on a reference chart; record each adjustment and result. After a simulated spray session using waterborne basecoat, disassemble the gun, flush with manufacturer-recommended gun wash, clean all passages with a brush kit, reassemble, and demonstrate correct solvent-waste disposal into the labeled container.	HVLP, LVLP, and conventional spray guns; fluid tip and air-cap sets; in-line pressure gauge; masking paper; gun cleaning kit; approved gun wash; labeled solvent-waste container; manufacturer gun manuals; I-CAR REF07 reference	Test pattern on masking paper shows an elliptical fan within 10% width uniformity and consistent wet edge; gun disassembly/reassembly completed in correct sequence with no leaks at operating pressure; cleaning procedure observed as pass/fail with zero contaminated waste disposal errors.
7	Basecoat Application: Solid, Metallic, and Pearl Colors	22	lab	Students will apply solvent-borne and waterborne basecoat in solid, metallic, and tri-coat pearl formulations to test panels at the correct film build and spray technique so that metallic orientation and hiding are uniform across the panel.	Apply a solid-color basecoat to a 24×18-inch practice panel using the mist-coat/full-coat technique specified in the TDS; evaluate hiding by placing a contrast card behind an unprimed corner until opacity is confirmed, then apply one additional control coat. Apply a mid-coat metallic basecoat using reduced pressure and increased distance for the orientation coat; photograph the panel under shop lighting and compare metallic uniformity against the manufacturer's standard chip under the same light. Apply a three-stage pearl midcoat over a silver basecoat and under a clearcoat on a small panel; evaluate for mottle and use a mini-flake orientation coat as needed; document pass/fail judgment in the lab log with reasoning.	Solvent-borne and waterborne basecoat (solid, metallic, pearl); reducers matched to ambient temperature; HVLP guns with appropriate fluid tips; 24×18-inch primed steel practice panels; contrast cards; manufacturer color chips; digital camera; lab log binders; spray booth	Instructor evaluates hiding (no substrate visible), uniformity of metallic orientation (no mottle or tiger striping), and absence of sags/runs using a 6-point rubric; minimum pass is 80% of total rubric points; lab log entry submitted for each color type.
8	Clearcoat Application and Blending	18	lab	Students will apply two-component urethane clearcoat at the correct film build and blending edge technique so that gloss, distinctness of image (DOI), and adhesion meet shop-quality standards.	Mix two-component clearcoat to the manufacturer's ratio using a gram scale, add the specified reducer volume, pot-life-label the cup, and apply two full wet coats with the manufacturer's inter-coat flash time to a basecoated panel. Practice the blending-edge technique on an adjacent primed panel: apply full clearcoat to the repair zone and feather out into the blend zone using a reducer spray to melt the edge, achieving an invisible transition line. After bake and cool-down, use a gloss meter and a DOI gauge to record readings on the cleared panel and compare to the manufacturer's target values; document readings in the lab log.	Two-component urethane clearcoat; activator; reducer (fast, medium, slow); HVLP gun; gram scale; mixing cups; pot-life labels; gloss meter; DOI gauge; basecoated practice panels; spray booth; manufacturer TDS; lab log binders	Gloss meter reading at 60° meets or exceeds manufacturer's published gloss target; no sags, solvents pop, or dry-spray visible under raking light; blending edge rated invisible by instructor at arm's length; lab log submitted with all measurements.
9	Color Theory and Spectrophotometer-Based Color Matching	16	theory	Students will use a spectrophotometer and paint manufacturer's electronic color-retrieval system to identify an OEM color code, retrieve formula variants, and select the variant that best matches a sample panel under standard D65 illumination.	Lecture and diagram: review the color wheel, hue/value/chroma dimensions, and the effect of metallic flop angle; students complete a 10-question color-theory worksheet. Using a spectrophotometer, scan a painted test panel at three angles; enter the data into the manufacturer's color-retrieval software, review the ranked variant list, and select the closest variant; document the OEM code and variant number. Spray three drawdown cards from the top-ranked, second-ranked, and an intentionally mis-selected variant; evaluate under standard D65 lamp and incandescent source; record the correct selection and justify the choice in writing.	Spectrophotometer (multi-angle); manufacturer color-retrieval workstation or tablet software; D65 color-matching lamp; incandescent lamp; drawdown cards; HVLP spray gun; at least two basecoat variants per exercise panel; color theory worksheet; I-CAR COR03 reference	Written color-theory worksheet scored 80% or above; correct variant selected and justified in writing for at least 4 of 5 panel exercises; instructor confirms drawdown evaluation under D65 lamp matches written selection.
10	Paint Defect Identification and Correction	20	lab	Students will identify at least eight common refinish defects by cause and symptom and correct them using wet sanding, compounding, and polishing procedures to restore surface gloss without cutting through to basecoat.	Match 12 photographs of defects (orange peel, fisheye, solvent pop, runs/sags, dirt nib, blush, lifting, adhesion failure, die-back, featheredge mapping, sand scratch swelling, water spotting) to a defect description card; explain probable cause and prevention for each. Wet-sand a panel exhibiting orange peel and a dirt nib using 1500- and 2000-grit wet/dry paper on a foam pad, checking progress with a gloss meter every 5 minutes until peel is removed without cut-through confirmed by dry-film gauge. Machine-compound and polish the wet-sanded panel using a dual-action polisher with cutting compound followed by finishing polish and a foam finishing pad; final gloss meter reading and DOI reading recorded in lab log.	Pre-defected practice panels (orange peel, dirt nib, solvent pop, runs); 1500- and 2000-grit wet/dry sandpaper; foam wet-sand pads; dual-action polisher; cutting compound; finishing polish; foam cutting and finishing pads; dry-film thickness gauge; gloss meter; defect photo-card set; lab log binders	Defect-card matching scored 10 of 12 or better; post-polishing gloss meter reading at 60° within 10 gloss units of an undamaged adjacent panel; no cut-through confirmed by dry-film gauge reading remaining above minimum clearcoat film build; lab log submitted.
11	Masking, Overspray Control, and Vehicle Protection	16	demo	Students will mask a vehicle for a spot repair and a full panel refinish using tape, paper, and plastic sheeting so that no overspray, tape adhesive, or heat damage occurs on unrepaired surfaces.	Demonstrate and then practice back-masking a door jamb using fine-line tape and masking paper, ensuring no tape edge is exposed to direct overspray; instructor critiques and students re-do any lifted tape sections. Mask an entire adjacent door panel for a blend repair—covering glass, trim, and adjacent panels—using the correct tape, jamb masking, and plastic sheeting; photograph the completed mask-up before applying sealer. Simulate a tape-pull error (tape left too long, baked) on a scrap panel; demonstrate safe tape removal technique at 45° with low heat from a heat gun; document the result and corrective action in the lab log.	Fine-line tape (6 mm and 19 mm); masking tape; automotive masking paper (18-inch roll); plastic masking sheeting; masking machine; heat gun; practice vehicle or vehicle section; camera; lab log binders	Instructor inspects completed mask-up using a light probe inside jambs—zero tape-edge exposure to spray zone; no lifted tape edges; glass and chrome trim covered fully; evaluated on a 4-criterion pass/fail rubric; all criteria must pass.
12	Final Refinish Quality Inspection and Documentation	16	field	Students will perform a complete final quality inspection of a refinished vehicle panel using industry-standard measurement tools and document all findings on a repair order, accepting or rejecting the job to shop-quality standards.	Using a dry-film thickness gauge, gloss meter, and raking light, inspect a refinished panel at 10 prescribed measurement points; record all readings on a quality-control form and compare to target ranges. Walk around a completed practice vehicle with an industry mentor or employer guest; identify any color mismatch, texture variation, masking defects, or overspray; document each finding by location, type, and severity on a written punch-list. Simulate a customer delivery walkthrough: present the panel to a classmate acting as the customer, explain the repair performed, demonstrate gloss and color match, and answer two scenario questions about warranty and follow-up care.	Dry-film thickness gauge; gloss meter; quality-control inspection form; raking light or portable work light; refinished practice vehicle or panel; repair order forms; I-CAR REF course completion checklist; ASE B2 task list	Quality-control form completed with all 10 measurement points recorded; all readings within acceptable range or documented as a punch-list item with corrective action noted; customer walkthrough rated satisfactory by instructor on a 5-point rubric with minimum 4 of 5 points.

Assessments

Assessment	Type	Weight	Pass standard	Method & rubric
Refinish Theory Knowledge Exam	Written exam	25%	75% correct (38 of 50 questions)	A 50-question written exam covering paint chemistry, VOC regulations, spray gun mechanics, color theory, defect causes, and SDS interpretation, mapped to ASE B2 (Painting and Refinishing) task areas and I-CAR REF knowledge objectives. Questions include multiple-choice and short-answer formats; students have 90 minutes. Standard met · Safety · Time · Quality/finish · Documentation
Spray Application Skills Demonstration	Skills demonstration	45%	Minimum 80% of rubric points (24 of 30) with zero safety violations	Students refinish a designated 18×24-inch panel through the full sequence—surface prep, primer, sealer, basecoat, and clearcoat—within a 4-hour practical session observed by the instructor. A 6-criterion rubric evaluates surface prep quality, film build, color match, absence of defects, blending edge, and final polish; any personal-safety violation (missing respirator, ungrounded gun) is an automatic fail. Standard met · Safety · Time · Quality/finish · Documentation
Refinish Lab Log	Log	15%	Complete entries for all 8 lab lessons; average score of 80% or higher across entry rubrics	Students maintain a running lab log with dated entries for every lab and field lesson, including photographs, instrument readings (film build, gloss, temperature/humidity), product TDS references, and a brief reflection on technique adjustments made. The log is collected at the end of the course and scored for completeness, accuracy of recorded measurements, and quality of self-assessment notes. Standard met · Safety · Time · Quality/finish · Documentation
Refinish Safety Compliance Check	Safety audit	15%	Pass all 8 critical items; no single critical failure permitted	A structured observation checklist administered at the start of the skills demonstration in which the instructor verifies that the student correctly dons supplied-air or cartridge respirator (seal-checked), selects correct PPE for the material in use, verifies spray booth airflow before spraying, labels and segregates solvent waste, and performs lockout/tagout on booth exhaust fan before cleaning. Failure of any single critical item requires remediation and a re-check before the student may proceed. Standard met · Safety · Time · Quality/finish · Documentation

TRN-AUTO25-06 Trade course

Collision Repair Estimating

204 hr · ~~$2,940~~ COMPLIMENTARY

Students learn to produce accurate, professional repair estimates using industry-standard estimating systems, OEM and aftermarket parts sourcing, and labor time guides, applying both manual and software-based methods. The course covers damage analysis, total-loss evaluation, supplement writing, insurer communication, and customer relations as they apply to the collision repair workflow. Lesson content maps directly to I-CAR ProLevel estimating competencies and ASE B-series knowledge areas related to damage analysis and repair planning.

Outcomes

Perform a systematic vehicle damage analysis and document all affected panels, structural components, and mechanical items using accepted collision industry inspection methods.
Produce a complete written repair estimate using industry estimating software (CCC ONE or equivalent) that correctly applies labor times, part prices, and refinish calculations to within 10% of an instructor-prepared benchmark.
Identify and correctly classify parts as OEM, OE-equivalent (aftermarket), recycled (LKQ), or remanufactured, and justify selection based on insurer guidelines, repair standards, and customer authorization.
Write a supplement identifying hidden or additional damage discovered during teardown and explain each line item to a simulated insurer and customer audience.
Evaluate a vehicle for total-loss threshold using the insurer's total-loss formula concept and document findings with supporting cost data.
Demonstrate professional written and verbal communication with simulated insurers, customers, and parts suppliers, including cycle-time commitments and authorization documentation.

Course text

How the course runs. 12 blocks: The Estimate's Role in the Collision Repair Cycle; Damage Analysis: Walk-Around and Inspection Methods; Reading and Using Labor Time Guides; Parts Classification and Sourcing; Refinish Time Calculations and Paint Materials Allowances; Building a Complete Estimate in Estimating Software; Supplement Writing: Identifying and Documenting Hidden Damage; Total-Loss Evaluation and Documentation; Insurer Relations, DRP Agreements, and Negotiation; Customer Communication: Explaining Estimates, Authorizations, and Cycle Time; Digital Documentation, Photo Standards, and File Management; Estimating Capstone: Full Vehicle Estimate, Supplement, and Presentation.

What competent looks like. Perform a systematic vehicle damage analysis and document all affected panels, structural components, and mechanical items using accepted collision industry inspection methods. Produce a complete written repair estimate using industry estimating software (CCC ONE or equivalent) that correctly applies labor times, part prices, and refinish calculations to within 10% of an instructor-prepared benchmark. Identify and correctly classify parts as OEM, OE-equivalent (aftermarket), recycled (LKQ), or remanufactured, and justify selection based on insurer guidelines, repair standards, and customer authorization. Write a supplement identifying hidden or additional damage discovered during teardown and explain each line item to a simulated insurer and customer audience. Evaluate a vehicle for total-loss threshold using the insurer's total-loss formula concept and document findings with supporting cost data. Demonstrate professional written and verbal communication with simulated insurers, customers, and parts suppliers, including cycle-time commitments and authorization documentation.

Lessons · 12 blocks

#	Lesson	Hr	Type	Objective	Activities	Materials	Check
1	The Estimate's Role in the Collision Repair Cycle	11	theory	Students explain how the written estimate connects initial damage analysis, parts ordering, technician workflow, insurer payment, and customer authorization in a complete repair cycle.	Trace a sample repair order packet—DRP agreement, estimate, authorization form, supplement, and final invoice—through each stage of a shop workflow map drawn by students on a whiteboard. Read and annotate an actual (de-identified) closed repair file and identify the point at which each document was created, who signed it, and what triggered the next step. Small-group discussion: students list three things that go wrong when an estimate is inaccurate and present one real consequence (customer dispute, parts delay, supplement denial) from scenarios provided.	Sample de-identified repair file packet, shop workflow diagram handout, whiteboard, I-CAR Estimating course reference materials, Mitchell or CCC ONE product overview brochure	Exit-ticket quiz: 8 multiple-choice questions covering repair-cycle stages, document types, and stakeholder roles; pass = 6/8 correct.
2	Damage Analysis: Walk-Around and Inspection Methods	16.5	demo	Students perform a structured walk-around inspection on a collision-damaged vehicle and document all visible and suspected hidden damage on a standardized inspection worksheet.	Instructor demonstrates the 360-degree walk-around sequence on a wrecked vehicle, narrating each zone (front clip, A-pillar, rocker, quarter, rear clip, glass, mechanical) while students annotate a blank vehicle diagram. Students practice the inspection in pairs on two different damaged vehicles in the shop, completing a written damage worksheet for each vehicle independently. Pairs compare worksheets and reconcile discrepancies, then instructor reviews the master damage list and explains how missed items become missed lines on the estimate.	Two collision-damaged vehicles, standardized damage inspection worksheet (instructor-created), vehicle zone diagram handout, flashlight, inspection mirror, measuring tape, gloves, safety glasses	Instructor reviews each student's completed damage worksheet against the master; pass = identification of at least 85% of listed damage items with correct zone and component labeling.
3	Reading and Using Labor Time Guides	14.5	theory	Students locate R&I (remove and install), R&R (remove and replace), and repair labor times for at least five body components in a standard estimating database and explain what those times include and exclude.	Instructor walks through the structure of the CCC ONE or Mitchell labor time database—vehicle selection, operation types, included/not-included notes, and overlap deductions—using a projected live session. Students use the estimating workstation to look up labor times for a hood, front door, quarter panel, front bumper cover, and windshield on an assigned vehicle year/make/model and record each time with its included/not-included notes. Class builds a comparison table showing R&I vs. R&R vs. repair times for the same five components and discusses when each operation is chosen and how overlap (blend, corrosion protection) affects the total.	Estimating workstation with CCC ONE or Mitchell estimating software license, labor time guide (printed excerpt as backup), projector, comparison table worksheet	Written quiz: students look up six assigned operations on the software and record times and included/not-included notes; pass = all six times within one-tenth of an hour of the database value and all included notes correctly stated.
4	Parts Classification and Sourcing	14.5	theory	Students classify a given list of collision parts as OEM, CAPA-certified aftermarket, recycled/LKQ, or remanufactured and identify one appropriate source for each classification.	Instructor presents the four part types using real examples (OEM hood, CAPA-certified aftermarket hood, LKQ door, remanufactured headlamp), explaining quality certifications (CAPA, NSF), warranty implications, and insurer allowances for each. Students receive a parts list for a front-end repair and use a parts-sourcing scenario sheet (simulating a parts locator and dealer quote) to select and justify the part type for each line, considering a DRP insurer guideline sheet provided. Role-play: one student is the estimator, one is the customer asking why a non-OEM part was chosen; students practice explaining quality, fit, and warranty in plain language.	Physical part samples or high-resolution photos of OEM vs. aftermarket parts, CAPA certification overview handout, insurer DRP guideline scenario sheet, parts-sourcing exercise worksheet	Parts-classification worksheet scored by instructor; pass = correct classification and justification for at least 10 of 12 parts, with at least one appropriate source named for each.
5	Refinish Time Calculations and Paint Materials Allowances	14.5	theory	Students calculate refinish labor times and paint materials costs for a multi-panel repair using blend, panel, and two-tone operations as defined in the estimating system.	Instructor demonstrates how the estimating system calculates refinish time—panel time, blend time, two-tone add-on, jamb time, clear-coat add-on—using a projected vehicle estimate with four damaged panels. Students complete a refinish calculation worksheet for an assigned three-panel scenario (quarter panel, door, rear bumper cover) requiring a blend on an adjacent door, calculating labor and paint materials allowance per the system formula. Students peer-review each other's worksheets, then the instructor reveals the system-generated figure and leads a discussion on common discrepancies (forgetting blend, miscounting adjacent panels).	Estimating workstation, refinish time calculation worksheet, paint materials allowance chart (from estimating system documentation), projector	Refinish calculation worksheet: pass = final labor hours within 0.5 hour of system output and paint materials cost within 5% of system output for all panels.
6	Building a Complete Estimate in Estimating Software	22	lab	Students produce a complete, printable estimate for a real collision-damaged vehicle using CCC ONE or equivalent software that correctly includes all labor, parts, refinish, and sublet lines.	Each student inspects an assigned damaged vehicle using the walk-around method from Lesson 2, then enters the damage into the estimating software from scratch, selecting the correct vehicle profile, all damaged parts, and applicable operations. Students cross-check their estimate against the software's internal audit flags (missing related operations, overlapping labor) and correct flagged items before printing. Students present their printed estimate to the instructor in a brief five-minute verbal walkthrough, explaining three estimate line choices (why R&R vs. repair, why blend was added, why a sublet line was included).	Two collision-damaged vehicles (different from Lesson 2 vehicles), estimating workstation, CCC ONE or Mitchell software, inspection worksheet, printer, safety glasses, gloves	Instructor scores printed estimate against a master estimate using a 20-point rubric (vehicle identification, all major damage lines present, correct operation types, refinish complete, sublet noted where needed); pass = 16/20 points and verbal walkthrough demonstrates understanding of three questioned lines.
7	Supplement Writing: Identifying and Documenting Hidden Damage	16.5	lab	Students write a supplement documenting at least four items of additional damage discovered during a simulated teardown and justify each supplement line with a damage explanation note.	Instructor demonstrates a teardown supplement on a partially disassembled vehicle, showing how hidden damage (bent inner apron, cracked radiator support, damaged wiring harness) is photographed, measured, and entered as supplement lines with notes. Students disassemble assigned front-clip components (bumper cover off, grille removed, hood open) on a shop vehicle under supervision, photograph damage found, and add supplement lines to their existing estimate from Lesson 6. Students write a brief supplement narrative (three to five sentences) explaining the additional damage to a simulated insurer, which is peer-reviewed for clarity and completeness.	Partially disassembled collision-damaged vehicle, hand tools (trim removal tools, sockets), digital camera or smartphone for documentation, estimating workstation, supplement narrative worksheet, PPE (gloves, safety glasses)	Supplement reviewed by instructor: pass = at least four additional damage lines entered correctly in software, each with a written damage explanation note, and supplement narrative is factually accurate and free of unsupported claims.
8	Total-Loss Evaluation and Documentation	13	theory	Students apply the total-loss threshold concept to three vehicle scenarios and recommend total-loss or repair with a written rationale supported by repair cost and vehicle value data.	Instructor explains the total-loss formula concept (repair cost relative to actual cash value), introduces how insurers and states generally define total-loss thresholds without citing a specific statutory percentage, and shows a sample total-loss settlement worksheet. Students receive three scenario packets, each with a completed estimate, a NADA/Black Book value printout, and salvage value estimate; students calculate whether each vehicle crosses the threshold and write a one-paragraph rationale. Class debrief: instructor reveals the insurer decision for each scenario and facilitates discussion on borderline cases, owner-retain options, and salvage title implications.	Three total-loss scenario packets (instructor-prepared with fictional vehicle data), sample total-loss settlement worksheet, NADA Guides or Black Book reference (printed excerpt), total-loss decision worksheet	Written rationale graded on a 10-point rubric (correct threshold comparison, accurate math, logical conclusion, professional language); pass = 7/10 on all three scenarios.
9	Insurer Relations, DRP Agreements, and Negotiation	13	theory	Students explain the obligations and limitations imposed on a shop by a Direct Repair Program agreement and demonstrate one professional negotiation technique for a disputed labor time or part type.	Students read a sample (fictional) DRP agreement highlighting parts-type requirements, labor rate caps, cycle-time standards, and customer-satisfaction scoring, then annotate it for three items that affect how an estimate is written. Instructor role-plays an insurer desk reviewer disputing a labor line; students take turns as the estimator using the estimating system's included/not-included documentation and I-CAR position statements to support the line. Small groups draft a written position statement (four to six sentences) defending a disputed refinish blend charge using industry documentation as support, then share with the class for critique.	Sample fictional DRP agreement, I-CAR position statements (printed excerpts), estimating system documentation on included/not-included operations, position statement worksheet	Written position statement scored on a 6-point rubric (accurate use of industry documentation, professional tone, clear argument, specific line-item reference); pass = 4/6 points.
10	Customer Communication: Explaining Estimates, Authorizations, and Cycle Time	13	demo	Students conduct a simulated customer estimate presentation that covers all damage, part choices, payment process, and cycle-time commitment using clear, non-technical language.	Instructor demonstrates a full customer estimate presentation (five minutes) on camera using the printed estimate from Lesson 6, modeling plain-language explanations of each section, how to handle a customer objection, and how to obtain a written authorization signature. Each student conducts a five-minute estimate presentation to a classmate playing the role of a skeptical customer; presentations are recorded for self-review. Students review their recording and complete a self-assessment checklist (covered all damage, explained part choice, gave cycle time, obtained simulated authorization) and identify one area to improve.	Printed estimate from Lesson 6, customer authorization form (blank), recording device (smartphone or webcam), self-assessment checklist, instructor scoring rubric	Instructor scores live presentation on a 10-point rubric (all damage sections addressed, part type explained, cycle time stated, authorization form explained, professional communication); pass = 7/10.
11	Digital Documentation, Photo Standards, and File Management	14.5	practice	Students compile a complete digital repair file—including estimate, supplement, vehicle photos meeting insurer photo standards, authorization, and parts invoices—organized in a folder structure that meets shop documentation requirements.	Instructor demonstrates insurer photo standards (four corners, odometer, VIN, damage close-ups, parts-off photos, in-process photos) using a complete sample photo set, explaining why each photo type is required. Students photograph an assigned damaged vehicle following the insurer photo standard checklist, upload images to the class shared drive, and attach them to their estimate file in the estimating software. Students organize all documents from Lessons 6 and 7 into a labeled digital folder (estimate, supplement, photo set, authorization, parts sourcing sheet) and submit the folder link or export for instructor review.	Damaged vehicle from previous lessons, smartphone or digital camera, insurer photo standard checklist (instructor-prepared based on common industry practice), estimating software, class shared drive or LMS file submission	Instructor audits submitted digital file: pass = all required photo types present and in focus, estimate and supplement included, folder structure correctly labeled, minimum 85% of photo-standard checklist items met.
12	Estimating Capstone: Full Vehicle Estimate, Supplement, and Presentation	41	lab	Students independently produce and defend a complete repair estimate package—including initial estimate, teardown supplement, digital photo file, and written customer summary—for an unfamiliar collision-damaged vehicle to a professional standard.	Students independently inspect an assigned vehicle they have not previously worked on, produce a complete initial estimate in the estimating software within one class session, and submit it for a preliminary instructor review without assistance. Students perform a supervised partial teardown to discover hidden damage, write and enter a supplement, update the photo file, and prepare a written customer summary explaining the full scope of repair, part choices, and estimated completion time. Students deliver a ten-minute formal presentation of their complete estimate package to the instructor and two peers acting as an insurer reviewer and a customer, defending line items using industry documentation when challenged.	Unfamiliar collision-damaged vehicle (not previously used in course), estimating workstation, estimating software, hand tools, digital camera, printer, customer summary template, instructor scoring rubric, PPE (gloves, safety glasses)	Instructor scores estimate package on a 30-point rubric across five categories (damage completeness 6 pts, labor accuracy 6 pts, parts classification 6 pts, supplement accuracy 6 pts, presentation and communication 6 pts); pass = 22/30 overall with no category below 3/6.

Assessments

Assessment	Type	Weight	Pass standard	Method & rubric
Estimating Theory Knowledge Exam	Written exam	25%	75% correct (30 of 40 questions)	A 40-question written exam covering labor time guide interpretation, parts classification, refinish calculation rules, total-loss concepts, DRP obligations, and the repair cycle, mapped to I-CAR estimating competency areas and ASE B-series damage analysis knowledge. Students must achieve 75% to pass; a single retake is permitted after a remediation session. Standard met · Safety · Time · Quality/finish · Documentation
Live Estimate Software Skills Demonstration	Skills demonstration	45%	Instructor rubric score of 16/20 or higher with no critical omissions (missing VIN, missing all structural lines, or zero refinish lines each constitute a critical omission requiring a retake)	Each student produces a complete estimate on an assigned vehicle in the estimating software within a timed session, covering vehicle identification, all damage lines, correct operation types, refinish, and at least one sublet or part-type justification note. The instructor evaluates the printed estimate using a 20-point rubric and conducts a five-minute oral questioning on three chosen line items. Standard met · Safety · Time · Quality/finish · Documentation
Estimating Lab Log	Log	15%	All 12 lesson lab entries submitted; average score of 80% across scored entries; no entry rated unsatisfactory	Students maintain a sequential lab log documenting each hands-on lesson activity: damage inspection worksheets, software screenshots or printouts, supplement notes, photo logs, and reflection notes on errors and corrections. Each entry is scored on completeness, accuracy, and self-reflection depth using a four-point rubric, confirming that practical work was performed and understood. Standard met · Safety · Time · Quality/finish · Documentation
Workplace Documentation and Safety Compliance Check	Safety audit	15%	100% compliance on all safety and documentation mandatory items; any failure requires immediate correction and re-check before the student may continue lab work	Instructor conducts a structured check at the start of the capstone lab verifying that the student correctly wears required PPE (safety glasses, gloves) when in the shop area, follows proper vehicle support procedures before any component removal, and has a complete, signed customer authorization form in hand before beginning teardown, mirroring the legal and safety requirements of an actual shop. Standard met · Safety · Time · Quality/finish · Documentation

TRN-AUTO25-07 Capstone

Capstone Project: Full-Cycle Collision Repair

216 hr · ~~$2,160~~ COMPLIMENTARY

Students apply every skill acquired in the program—frame measurement and straightening, panel repair and replacement, MIG/MAG and squeeze-type resistance welding, primer-sealer application, color matching, and refinishing—to a single, industry-realistic damaged vehicle or unibody shell assigned by the instructor. Work is documented with a written repair plan, a completed CCC ONE or Mitchell estimate, and a photo log, then defended in a formal oral presentation to a panel of instructors and an industry evaluator. The course mirrors the workflow of a production collision shop and prepares students for I-CAR ProLevel role assessments and ASE B2, B3, B4, and B5 written exams.

Outcomes

Diagnose structural and cosmetic damage on an assigned collision-damaged vehicle, produce a documented repair plan that matches industry estimating standards, and justify repair-versus-replace decisions verbally.
Restore the vehicle's unibody or body-over-frame geometry to manufacturer specifications using a frame-pulling system and three-dimensional measuring equipment, recording all pull sequences and final dimensions.
Complete all required panel operations—straightening, filling, metal finishing, and replacement welding—so that panel gaps and surface contour meet OEM tolerances measurable with a body-line gauge and gap tool.
Apply primer-sealer, topcoat, and clear coat using proper spray technique and perform a color-match blending operation that passes a side-by-side spectrophotometer and visual evaluation under a color-correct light source.
Compile a complete repair portfolio that includes the initial damage assessment, final estimate, weld inspection checklist, paint-thickness readings, and time log, and present findings in a structured oral defense.
Demonstrate consistent safe-work practices throughout the project, including correct PPE selection, hazardous-material handling per SDS requirements, and respirator use verified by fit-test documentation.

Course text

How the course runs. 4 blocks: Damage Assessment, Repair Planning, and Estimating; Structural Repair and Panel Reconstruction; Refinishing: Primer, Color Match, and Topcoat Application; Portfolio Completion and Capstone Defense.

What competent looks like. Diagnose structural and cosmetic damage on an assigned collision-damaged vehicle, produce a documented repair plan that matches industry estimating standards, and justify repair-versus-replace decisions verbally. Restore the vehicle's unibody or body-over-frame geometry to manufacturer specifications using a frame-pulling system and three-dimensional measuring equipment, recording all pull sequences and final dimensions. Complete all required panel operations—straightening, filling, metal finishing, and replacement welding—so that panel gaps and surface contour meet OEM tolerances measurable with a body-line gauge and gap tool. Apply primer-sealer, topcoat, and clear coat using proper spray technique and perform a color-match blending operation that passes a side-by-side spectrophotometer and visual evaluation under a color-correct light source. Compile a complete repair portfolio that includes the initial damage assessment, final estimate, weld inspection checklist, paint-thickness readings, and time log, and present findings in a structured oral defense. Demonstrate consistent safe-work practices throughout the project, including correct PPE selection, hazardous-material handling per SDS requirements, and respirator use verified by fit-test documentation.

Lessons · 4 blocks

#	Lesson	Hr	Type	Objective	Activities	Materials	Check
1	Damage Assessment, Repair Planning, and Estimating	40	lab	Given an assigned damaged vehicle, the student will write a complete, documented repair plan and computer-generated estimate that identifies all structural and cosmetic damage, lists correct OEM part numbers or repair procedures, and falls within ten percent of the instructor's master estimate.	Perform a 360-degree visual and dimensional inspection of the assigned vehicle; photograph every damaged area and record findings on a damage-analysis worksheet, noting primary, secondary, and hidden damage zones. Use shop estimating software (CCC ONE or Mitchell Cloud Estimating) to build a line-item estimate, selecting repair or replace for each affected part based on damage severity guidelines from the I-CAR Damage Analysis course area; print and mark up the estimate with the instructor. Write a one-to-two page narrative repair plan that sequences all operations—frame pull, panel work, weld replacement, corrosion protection, and refinish—and identifies required consumables, safety measures, and estimated cycle time.	Assigned collision-damaged vehicle, inspection mirror, pry bar, tape measure, body-line gauge, gap tool, digital camera or smartphone, estimating workstation with CCC ONE or Mitchell software, OEM repair manual or ALLDATA subscription, I-CAR Damage Analysis reference guide, damage-analysis worksheets	Instructor compares student estimate line-by-line against master estimate; student must capture all structural damage items and be within ten percent of total labor and parts cost; narrative repair plan must include correct operation sequence and PPE/SDS callouts — both elements must be satisfactory to advance.
2	Structural Repair and Panel Reconstruction	96	lab	The student will restore the assigned vehicle's structural geometry to within OEM specification using a frame-pulling system and will complete all required panel straightening, metal finishing, welded panel replacement, and corrosion-protection steps so that final dimensions and surface contour pass instructor measurement.	Set up the vehicle on the frame rack, attach measuring system targets, take a baseline three-dimensional read, and execute a documented pull sequence—recording anchor points, pull direction, pull force, and dimensional readings after each major pull—until all measurements fall within two millimeters of the OEM datum. Perform panel straightening operations on assigned steel panels using picks, hammers, and a stud-welder dent-pulling kit; apply filler to no more than one-quarter inch depth, block-sand to 80-grit, and verify surface with a straightedge before progressing to guide-coat blocking at 180-grit. Complete at least one welded panel replacement using MIG/MAG plug welds or squeeze-type resistance spot welds per OEM specifications; apply weld-through primer before closing seams, apply seam sealer per OEM type and location, and apply cavity wax to enclosed sections; document each step on the weld inspection checklist.	Frame-pulling system with anchoring clamps, three-dimensional measuring system (laser or mechanical), OEM dimension spec sheet, MIG/MAG welder with 75/25 shielding gas, STRSW unit, weld-through primer, seam sealer, cavity wax, pneumatic grinder, pneumatic hammer, pick set, stud-welder kit, body filler, mixing board, spreaders, dual-action sander, block sand paper (80, 120, 180 grit), guide coat, gap tool, straightedge, torque wrench, OSHA-approved respirator and face shield, welding helmet rated for process in use	All structural dimensions must fall within the OEM tolerance (typically ± 2 mm) documented on a signed measurement printout; weld quality checked by instructor using destructive test coupon on a same-gauge sample (weld nugget must meet STRSW or MIG plug weld size standard); surface must show no high or low spots greater than the width of a business card under a straightedge; student earns satisfactory only when all three checks pass.
3	Refinishing: Primer, Color Match, and Topcoat Application	54	lab	The student will prepare all repaired surfaces, apply primer-sealer, mix a color-matched topcoat using spectrophotometer and spray-out card technique, and apply topcoat and clear coat so that the finished panels pass a side-by-side color match and a paint-thickness-gauge reading within the range specified by the coating manufacturer.	Block-sand all filled areas through 320-grit, featheredge surrounding OEM finish, clean and tack, then apply two coats of two-part primer-sealer; after cure, guide-coat block-sand to 400-grit, inspect for pinholes or sand scratches, and document surface readiness on the refinish log. Use a spectrophotometer to identify the starting formula for the vehicle's color code, adjust the formula based on spray-out card readings, spray three test panels at different film-build levels, evaluate under a color-correct light source, and select the best match before spraying the vehicle; record all formula adjustments. Apply topcoat and clear coat in the spray booth following the paint manufacturer's technical data sheet for flash times, film build, and temperature; after cure, perform machine compound and polish on the clear coat and measure dry film thickness with a paint-thickness gauge on five locations per panel.	Spray booth with HVLP or compliant spray guns, spectrophotometer, spray-out card stock, two-part primer-sealer, topcoat basecoat and clearcoat system, paint mixing scales accurate to 0.1 g, agitators, tack cloths, masking paper and tape, dual-action sander with 320- and 400-grit discs, guide coat, paint-thickness gauge, color-correct light source (5000 K minimum), machine polisher, compound, polish, microfiber towels, solvent-resistant nitrile gloves, NIOSH-approved organic-vapor respirator, SDS binder	Color match evaluated side-by-side with adjacent OEM panels under a 5000 K light source by instructor and an industry-panel evaluator — a visible hue or value mismatch is a fail; dry film thickness readings on all five locations per panel must fall within the coating manufacturer's specified range printed on the TDS; any runs, sags, or unpolished areas are a fail; all three criteria must pass.
4	Portfolio Completion and Capstone Defense	26	field	The student will assemble a complete repair portfolio and deliver a structured oral defense to a panel of at least two evaluators, explaining every major decision made during the project and responding correctly to technical questions drawn from I-CAR ProLevel and ASE B-series exam content areas.	Compile the full repair portfolio in digital or physical form: cover sheet with vehicle information, initial photo log, damage-analysis worksheet, final estimate printout, repair plan narrative, signed frame-measurement printout, weld inspection checklist, refinish log, paint-thickness-gauge readings, time log, and a one-page reflective summary comparing planned versus actual hours and costs. Prepare and deliver a ten-to-fifteen minute structured presentation using the completed vehicle as a visual aid; present the damage assessment findings, explain at least three key repair decisions with technical justification, walk evaluators through the completed estimate, and identify any lessons learned. Respond to a minimum of ten minutes of evaluator questions covering topics from the project; questions are drawn from I-CAR ProLevel Collision Repair Technician role competencies and ASE B2 (Painting and Refinishing), B3 (Non-Structural Analysis and Damage Repair), B4 (Structural Analysis and Damage Repair), and B5 (Mechanical and Electrical Components) exam content areas as relevant to work performed.	Completed capstone vehicle, assembled portfolio (digital folder or binder), projector or large monitor for photo display, portfolio checklist, evaluator scoring rubric, I-CAR ProLevel competency reference, ASE B-series task list (current edition), whiteboard for diagram use during defense	Portfolio is scored on the instructor rubric — all required documents must be present and complete; presentation must be delivered within the time limit with clear technical accuracy; oral Q&A scored on the evaluator rubric requiring correct or substantially correct responses on at least eight of ten questions; a score below satisfactory on any single rubric section requires remediation and one re-defense opportunity within two weeks.

Assessments

Assessment	Type	Weight	Pass standard	Method & rubric
Capstone Vehicle Project	Project	60%	All four instructor-checked quality gates (estimate accuracy, structural dimensions, weld quality, refinish finish quality) must be rated satisfactory; no gate may remain unsatisfactory at project closeout.	The primary summative assessment is the completed collision-damaged vehicle itself, evaluated against OEM specifications and industry quality standards at each production stage—frame geometry, panel surface, weld quality, and paint finish—using the same measurement tools and acceptance criteria used in a production collision shop. Meets specification · Within estimate · Workmanship · Safety · Documentation
Repair Portfolio	Portfolio	20%	All required documents must be present; narrative sections must demonstrate accurate technical reasoning; overall rubric score of 80 percent or higher required to pass.	The repair portfolio collects every document generated during the project—damage assessment photos, estimate, repair plan, measurement printouts, weld and refinish logs, time records, and a reflective summary—and is scored on a rubric that evaluates completeness, accuracy, professional format, and the quality of the student's written technical reasoning. Completeness · Organization · Evidence quality
Capstone Oral Defense	Oral / panel	20%	Presentation delivered within time limit with no critical technical errors; oral Q&A must achieve at least eight correct responses out of ten evaluator questions; one re-defense permitted within two weeks if not passed on first attempt.	The student presents the completed project to a panel of at least two evaluators—an instructor and an industry representative—explains major repair decisions with technical justification, and responds to questions drawn from I-CAR ProLevel Collision Repair Technician competencies and the relevant ASE B-series task lists, demonstrating readiness for employment and credentialing exams. Explains decisions · Answers technical questions · Professional communication

TRN-AUTO25-08 Externship / clinical

Externship / Worksite Placement

324 hr · ~~$1,295~~ COMPLIMENTARY

Students complete 324 supervised hours at a licensed auto body and collision repair facility, applying classroom skills to real customer vehicles under the direct oversight of a journeyman technician or shop supervisor. Worksite experience spans metal repair, welding, refinishing, estimating, and customer-vehicle documentation, bridging school training to industry employment. An employer evaluation and a reflective field log are used to verify occupational competency at industry standards.

Outcomes

Perform assigned collision repair tasks—including panel straightening, MIG welding, and refinish preparation—on customer vehicles to shop quality standards under journeyman supervision.
Apply proper PPE selection, lockout/tagout procedures, and hazardous-material handling protocols in a live shop environment without prompting.
Interpret a repair order and a CCC ONE or Mitchell estimating printout to sequence tasks and track labor time for a real repair job.
Demonstrate professional workplace behaviors—punctuality, communication, toolbox accountability, and shop housekeeping—as rated satisfactory or better on the employer mid-term and final evaluations.
Document daily worksite activities, skills practiced, and self-assessed learning gaps in a structured field log that meets program submission requirements.
Identify at least two areas for continued skill development and connect them to specific I-CAR ProLevel or ASE B-series exam content areas reviewed in the following course.

Course text

How the course runs. 4 blocks: Worksite Orientation and Safety Integration; Applied Collision Repair Tasks — Metal, Welding, and Structural Work; Applied Refinishing, Estimating, and Customer-Vehicle Documentation; Field Log Review, Self-Assessment, and Employer Final Evaluation.

What competent looks like. Perform assigned collision repair tasks—including panel straightening, MIG welding, and refinish preparation—on customer vehicles to shop quality standards under journeyman supervision. Apply proper PPE selection, lockout/tagout procedures, and hazardous-material handling protocols in a live shop environment without prompting. Interpret a repair order and a CCC ONE or Mitchell estimating printout to sequence tasks and track labor time for a real repair job. Demonstrate professional workplace behaviors—punctuality, communication, toolbox accountability, and shop housekeeping—as rated satisfactory or better on the employer mid-term and final evaluations. Document daily worksite activities, skills practiced, and self-assessed learning gaps in a structured field log that meets program submission requirements. Identify at least two areas for continued skill development and connect them to specific I-CAR ProLevel or ASE B-series exam content areas reviewed in the following course.

Lessons · 4 blocks

#	Lesson	Hr	Type	Objective	Activities	Materials	Check
1	Worksite Orientation and Safety Integration	40	field	The student will demonstrate compliance with the host shop's safety policies, hazard communication program, and emergency procedures before performing any hands-on repair work.	Complete the employer's new-employee safety orientation and sign the acknowledgment form; review the shop's SDS binder, eyewash station locations, fire extinguisher types, and emergency exit routes with the site supervisor. Shadow the supervisor for a full repair-order cycle—vehicle check-in, damage documentation with photos, parts ordering, and work-in-progress tagging—and record observations in the field log. Perform a tool and equipment audit of the workstation assigned to the student (lift operation, MIG welder pre-use checklist, spray-booth air-supply check) and document any deficiencies reported to the supervisor.	Host-shop safety orientation packet, shop SDS binder, OSHA Hazard Communication Standard (29 CFR 1910.1200) summary, student field log booklet, smartphone or camera for photo documentation, PPE (respirator, safety glasses, gloves, shop coat)	Supervisor signs the shop orientation checklist confirming all safety stations were reviewed; student correctly identifies PPE required for at least three distinct tasks (welding, spray finishing, chemical stripping) on a verbal quiz administered by the supervisor — all three correct to pass.
2	Applied Collision Repair Tasks — Metal, Welding, and Structural Work	120	lab	The student will complete assigned metal straightening, MIG/squeeze-type resistance welding, and bolt-on or structural panel replacement tasks on customer vehicles to the quality level accepted by the shop supervisor.	Under journeyman direction, perform dollying, hammering, and stud-welding dent repair on assigned panels; log each vehicle RO number, task performed, time spent, and supervisor initials in the field log at the end of each shift. Replace at least one bolt-on or welded structural component (quarter panel section, uni-rail, or similar) following the OEM or I-CAR repair procedure for that vehicle; record the vehicle year/make/model and the reference procedure used. Assist with or independently perform sectioning, plug-welding, and seam-sealing on a replacement panel; measure and verify panel fit using a tram gauge or electronic measuring system before the supervisor approves the repair.	Shop MIG welder and consumables, squeeze-type resistance spot welder, hammer-and-dolly set, stud welder, tram gauge or electronic measuring system, angle grinder with cut-off and flap discs, I-CAR repair procedures (vehicle-specific), OEM body repair manuals accessed via the shop's OEM information subscription, student field log	Supervisor rates each completed task on the employer skills checklist (scale: Needs Assistance / Meets Standard / Exceeds Standard); student must receive Meets Standard or better on at least 80 percent of rated tasks in this phase to remain on track for a passing employer evaluation.
3	Applied Refinishing, Estimating, and Customer-Vehicle Documentation	120	lab	The student will prepare surfaces, mix and apply primer and topcoat materials, and assist with estimate writing and vehicle delivery documentation on at least two customer vehicles.	Sand, scuff, mask, and prime at least one repair area; mix paint using the shop's spectrophotometer and mixing scale to the paint manufacturer's formula; apply basecoat and clearcoat in the spray booth wearing supplied-air or appropriate air-purifying respirator, then blend and polish the repair to supervisor's acceptance. Using the shop's estimating system (CCC ONE, Mitchell, or Audatex), enter damage line items for one vehicle under supervisor guidance; compare the completed estimate to the original insurance appraisal and identify any supplements, then document the differences in the field log. Assist with quality-control inspection and customer vehicle delivery: walk the vehicle with the supervisor using a checklist for panel gaps, paint match, trim alignment, and glass seal; record any comeback or warranty items noted and the corrective action taken.	Dual-action and long-board sanders, DA polisher, spray gun (HVLP or compliant), spectrophotometer, paint mixing scale, masking paper and tape dispenser, shop paint line (waterborne or solvent-borne, per shop), CCC ONE / Mitchell / Audatex estimating terminal, vehicle-specific OEM color codes, supplied-air respirator or properly rated APF respirator, student field log	Supervisor rates surface prep, paint application, and polish quality on the skills checklist (same Meets Standard threshold as Lesson 2); student's estimate entry is checked by supervisor for correct labor-time entries and at least 80 percent of line items entered without error.
4	Field Log Review, Self-Assessment, and Employer Final Evaluation	44	field	The student will compile a complete, accurate field log, complete a structured self-assessment of skills gained and gaps remaining, and participate in a formal final evaluation conference with the site supervisor.	Organize and review all field log entries from the externship (RO numbers, tasks, hours, supervisor initials); total hours worked by category (structural, mechanical, refinish, estimating, other) and verify the running total matches 324 hours before submission. Complete a written self-assessment (one to two pages) identifying three skills demonstrated at industry standard, two skills requiring further development, and specific I-CAR ProLevel or ASE B-series exam content areas each gap connects to; submit the self-assessment with the field log to the program instructor. Participate in a scheduled final evaluation conference: the supervisor completes the program's Employer Final Evaluation form covering technical skill, safety behavior, professionalism, and work readiness; the student reviews ratings with the supervisor and signs the form, then the instructor debriefs the student on results and next steps in the certification exam preparation course.	Student field log booklet (all entries from Lessons 1–3), Employer Final Evaluation form, student self-assessment template, program hour-tracking spreadsheet, pen, copies of I-CAR ProLevel and ASE B-series exam content outlines (for self-assessment mapping)	Field log is complete with supervisor initials on every shift entry and total hours at or above 324; Employer Final Evaluation scores average Satisfactory or better (on a Needs Improvement / Satisfactory / Excellent scale) across all rated categories; self-assessment is submitted and addresses all three required elements — all three conditions must be met to pass the externship.

Assessments

Assessment	Type	Weight	Pass standard	Method & rubric
Employer Skills Evaluation (Skills Demonstration)	Skills demonstration	70%	Meets Standard or better on at least 80 percent of rated task items on both the mid-term and final Employer Skills Checklist, with no Needs Assistance ratings in any mandatory safety behavior item.	The host-shop supervisor observes and rates the student on a standardized skills checklist covering metal repair, welding, refinishing, estimating support, safety compliance, and professionalism at a mid-term check-in (approximately 160 hours) and again at the final evaluation (324 hours). Ratings are recorded on the program's Employer Skills Checklist form and returned to the school; a failed safety item triggers an immediate remediation plan before the student may continue. Competency · Safety · Attendance · Conduct · Initiative
Field Log and Self-Assessment (Lab Log)	Log	30%	Log is 100 percent complete (every shift entry dated, task described, RO or vehicle noted, and supervisor-initialed) and totals at least 324 hours; self-assessment addresses all required elements and is submitted no later than the last day of the externship.	The student maintains a daily field log throughout the externship recording vehicle RO numbers, tasks performed, time spent, and supervisor initials for every shift, and submits the completed log with a structured written self-assessment that maps identified skill gaps to I-CAR ProLevel and ASE B-series exam content areas. The program instructor reviews the log for completeness and accuracy, and uses the self-assessment to personalize the student's study plan for the Certification Exam Preparation course that follows. Complete · Verified

TRN-AUTO25-09 Exam prep

Certification Exam Preparation: ASE B-Series & I-CAR ProLevel

90 hr · ~~$900~~ COMPLIMENTARY

Students systematically review every content domain tested on the ASE B2–B6 and I-CAR ProLevel written exams, identify personal knowledge gaps through diagnostic practice, and complete timed full-length mock exams under realistic testing conditions. Emphasis is placed on applying trade knowledge built across the program to exam-style questions so that each student enters the credentialing exams with documented readiness.

Outcomes

Correctly answer at least 75% of practice questions in each ASE B-series exam domain (B2 Non-Structural Analysis and Damage Repair, B3 Painting and Refinishing, B4 Structural Analysis and Damage Repair, B5 Mechanical and Electrical Components, B6 Damage Analysis, Estimating, and Customer Service) on a timed mock exam.
Correctly answer at least 75% of practice questions covering each I-CAR ProLevel knowledge area (vehicle construction, repair planning, welding, refinish, and customer service fundamentals) on a timed mock exam.
Use a personal gap-analysis log to prioritize self-study in identified weak domains before the final mock exam.
Demonstrate test-taking strategies—question mapping, process of elimination, time management—that improve scored performance between the diagnostic and final mock exam.
Explain the registration process, eligibility requirements, exam format, and professional-conduct expectations for both the ASE B-series and I-CAR ProLevel credentials.
Construct a post-program professional development plan that identifies next credential steps and continuing-education pathways within the auto body and collision trade.

Course text

How the course runs. 4 blocks: Credential Orientation and Diagnostic Assessment; Domain-by-Domain Content Review: Structural, Non-Structural, Welding, and Mechanical; Domain-by-Domain Content Review: Refinishing, Estimating, and Customer Service; Full Mock Examinations and Professional Development Planning.

What competent looks like. Correctly answer at least 75% of practice questions in each ASE B-series exam domain (B2 Non-Structural Analysis and Damage Repair, B3 Painting and Refinishing, B4 Structural Analysis and Damage Repair, B5 Mechanical and Electrical Components, B6 Damage Analysis, Estimating, and Customer Service) on a timed mock exam. Correctly answer at least 75% of practice questions covering each I-CAR ProLevel knowledge area (vehicle construction, repair planning, welding, refinish, and customer service fundamentals) on a timed mock exam. Use a personal gap-analysis log to prioritize self-study in identified weak domains before the final mock exam. Demonstrate test-taking strategies—question mapping, process of elimination, time management—that improve scored performance between the diagnostic and final mock exam. Explain the registration process, eligibility requirements, exam format, and professional-conduct expectations for both the ASE B-series and I-CAR ProLevel credentials. Construct a post-program professional development plan that identifies next credential steps and continuing-education pathways within the auto body and collision trade.

Lessons · 4 blocks

#	Lesson	Hr	Type	Objective	Activities	Materials	Check
1	Credential Orientation and Diagnostic Assessment	10	theory	Students will describe the format, domain weighting, and registration requirements of the ASE B-series and I-CAR ProLevel exams and establish a personal gap-analysis baseline by completing and scoring a full diagnostic practice set.	Instructor-led walkthrough of the ASE B-series exam series (B2–B6): what each test covers, number of questions, time limits, passing score policy, and registration steps; followed by the same walkthrough for I-CAR ProLevel online and role-specific assessments. Students complete a 100-question timed diagnostic covering all ASE B-series domains and a separate 60-question I-CAR diagnostic; they self-score using an answer key and record domain-by-domain percentage correct on a printed gap-analysis worksheet. Class debrief: each student identifies their two lowest-scoring domains, writes a SMART study goal for each, and shares with a partner for peer accountability; instructor collects worksheets to inform pacing for Lessons 2 and 3.	Printed diagnostic question sets drawn from ASE-style practice banks and I-CAR training module review questions; gap-analysis worksheets; ASE candidate information bulletins; I-CAR ProLevel program overview documents; stopwatch or classroom timer; pencils.	Each student's gap-analysis worksheet must be complete with domain scores entered and two SMART goals written; instructor confirms all students understand exam registration steps by exit-ticket Q&A — 100% completion required to advance.
2	Domain-by-Domain Content Review: Structural, Non-Structural, Welding, and Mechanical	30	theory	Students will correctly answer practice questions at or above the 75% level in ASE B4 Structural Analysis, B2 Non-Structural Analysis, and B5 Mechanical and Electrical Components domains, and in the I-CAR vehicle construction and welding knowledge areas, by applying technical knowledge reinforced through targeted review sessions.	Rotating 90-minute focused review blocks (one per domain per session) using instructor-narrated slide decks tied directly to course content from Frame, Panel, and Welding courses; each block ends with 20 domain-specific practice questions completed individually, scored immediately, and discussed as a group with emphasis on why wrong answers are wrong. Hands-on reinforcement stations: students spend 30 minutes per session at labeled bench stations reviewing physical reference items — a sectioned unibody rocker demonstrating structural zones, a welded test coupon graded against AWS D1.1-style visual standards, an electrical schematic for a supplemental restraint system — then answer scenario-based practice questions about what they observed. Peer-teaching protocol: each student draws one assigned sub-topic (e.g., HSS sectioning procedures, MIG weld discontinuity types, SRS disable procedure) and delivers a 5-minute verbal explanation to a small group while the group evaluates accuracy against the course reference; instructor circulates and corrects misconceptions in real time.	Instructor-prepared review slide decks (mapped to I-CAR and ASE domain outlines); domain-specific practice question sets; sectioned vehicle body panels; welded test coupons; automotive wiring diagrams; I-CAR training module reference guides; ASE B4 and B5 task lists (available from ASE); whiteboard; highlighters.	End-of-lesson domain quiz: 20 questions per domain (B4, B2, B5, I-CAR structural/welding areas); students must score 75% or higher on each domain quiz; any student below 75% on a domain receives a targeted re-study assignment and a 10-question re-check quiz before the next lesson.
3	Domain-by-Domain Content Review: Refinishing, Estimating, and Customer Service	25	theory	Students will correctly answer practice questions at or above the 75% level in ASE B3 Painting and Refinishing and B6 Damage Analysis/Estimating/Customer Service domains, and in the I-CAR refinish and repair-planning knowledge areas, by applying technical and professional knowledge through targeted review and scenario practice.	Refinish domain deep-dive: instructor reviews color theory, paint system chemistry (primer, basecoat, clearcoat), surface preparation sequences, spray technique variables, and common defect causes and corrections; students match 20 defect photographs (orange peel, solvent pop, fisheye, dry spray, etc.) to cause-and-correction cards, then answer 25 ASE B3-style practice questions. Estimating and total-loss scenario workshop: pairs of students receive a printed vehicle damage photograph packet and a blank CCC ONE or Mitchell-style supplement worksheet; they write a structured damage narrative, identify applicable repair operations (repair vs. replace vs. blend decisions), and calculate a labor-and-parts line item list, then compare to an instructor-prepared answer sheet discussing typical exam question logic around estimating ethics and documentation. Customer service and professionalism role-play: students rotate through scripted scenarios (explaining a supplement to a customer, documenting a prior damage disclaimer, handling a warranty complaint) while peers score responses on a rubric aligned to ASE B6 and I-CAR customer-service competencies; debrief focuses on exam question language around technician responsibility and documentation requirements.	Paint defect photograph set; cause-and-correction reference cards (from manufacturer technical training materials); blank supplement worksheets; damage photograph packets; ASE B3 and B6 task lists; I-CAR refinish and repair-planning module references; role-play scenario cards; scoring rubrics; refinish product technical data sheets.	End-of-lesson domain quiz: 20 questions per domain (B3, B6, I-CAR refinish/repair-planning); students must score 75% or higher on each; the estimating scenario worksheet must include all required line items as defined by the answer key with no more than two omissions to pass; students below threshold complete a re-study assignment and re-check quiz.
4	Full Mock Examinations and Professional Development Planning	25	lab	Students will demonstrate exam readiness by scoring 75% or higher on a timed full-length ASE B-series mock exam and a timed I-CAR ProLevel mock exam administered under realistic testing conditions, and will produce a written professional development plan outlining their credential completion pathway.	Timed ASE B-series mock exam: students sit a 100-question multiple-choice exam (questions distributed across B2–B6 proportionally to approximate actual exam weighting) under strict testing conditions — no notes, timed by proctor, bubble-sheet answer format; exam is scored immediately and students receive a domain-by-domain score breakdown to compare against their Lesson 1 diagnostic results. Timed I-CAR ProLevel mock exam: students complete a 60-question multiple-choice assessment covering I-CAR knowledge areas (vehicle construction, repair procedures, welding, refinish, customer service) under the same proctored conditions; scored and reviewed as a class with instructor explaining the reasoning behind each commonly missed question. Professional development planning session: each student completes a one-page written plan that identifies (a) which ASE B-series exams they will sit first and target registration date, (b) their I-CAR ProLevel role track and next training module, (c) one area of continuing education (e.g., ADAS calibration, aluminum repair, waterborne refinish) relevant to their externship employer, and (d) a 12-month career milestone goal; plans are reviewed by instructor and returned with written feedback.	Full-length mock exam booklets (ASE B-series format, 100 questions; I-CAR format, 60 questions); bubble-sheet answer forms; proctor timer; answer keys with domain cross-references; professional development plan template; ASE registration instructions; I-CAR ProLevel enrollment guide; pens.	ASE B-series mock: 75% overall AND no individual domain below 70%; I-CAR mock: 75% overall; professional development plan: all four required sections complete with specific dates and credential names — instructor scores with a checklist and must approve the plan as complete; students who score below threshold on either mock exam receive an individualized remediation packet and may request a second attempt before program close-out.

Assessments

Assessment	Type	Weight	Pass standard	Method & rubric
Full Mock Certification Exam (ASE B-Series and I-CAR ProLevel)	Mock certification exam	100%	75% or higher overall on the ASE B-series mock with no individual domain below 70%, AND 75% or higher on the I-CAR ProLevel mock; professional development plan approved as complete by instructor.	Students complete a timed, proctored 100-question ASE B2–B6 mock exam and a timed, proctored 60-question I-CAR ProLevel mock exam under realistic credentialing test conditions, followed by submission of a written professional development plan. Scores are reported by domain so students and instructor can document readiness for the actual credentialing exams and identify any final areas requiring self-study before sitting. Score · Time management

Program completion

External credential: ASE B-series; I-CAR ProLevel

Students prepare for and sit I-CAR ProLevel credentialing assessments administered by the Inter-Industry Conference on Auto Collision Repair (I-CAR) and ASE B-series certification exams administered by the National Institute for Automotive Service Excellence (ASE). Pass standard: Credential issued by the body.

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