Non-structural analysis and damage repair section I

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Review damage report and analyze damage to determine appropriate methods for overall repair; develop and document a repair plan.

Lesson Plan for

CRT 130-1


Course HS Title:

Non-Structural Analysis and Damage Repair


KCTCS Courses included in HS Title: (Lesson is prepared for course highlighted.)

KCTCS Course No.

KCTCS Course Title



This lesson will instruct the student on how to review a damage report and analyze damage to determine appropriate methods for overall repair, and develop and document a repair plan. Knowledge of these techniques and the skills required to correct problems associated with this task are necessary for a student to acquire if they wish to compete for high paying, high skilled jobs in an Automotive Repair Facility. Entry level technicians need to be able to perform this task to 100% accuracy. Incorrectly performing this task can lead to an automobile accident or create customer satisfaction issues.

Prepared By



Grade Level

No. Students


Lesson Length:




Review damage report and analyze damage to determine appropriate methods for overall repair; develop and document a repair plan.




Given the proper tools and instruction, the student will be able to review a damage report and analyze damage to determine appropriate methods for overall repair, develop and document a repair plan, and pass a written test covering the task with 100% accuracy.


New Common Core:

RST 11-12-2

RST 11-12-3


New Common Core Technical



New Science Standards


Skills Standards:




Teacher Designed Materials and Other Handouts
Textbooks and Workbooks


Title/ISBN No.




James Duffy 

Auto Body Repair Technology 




James E. Duffy 

I-Car Professional Automotive Collision Repair 








As Needed

Paper (Estimate Paper) 


Content/Presentation/Demonstration Outline

 Instruct student that damage analysis involves locating all damage using a systematic series of inspections, measurements, and tests. This allows repairs to be done right the first time and it also prevents cost overruns. Before starting damage analysis, the student should: 1. If possible, discuss the collision with the owner or driver of the vehicle to obtain information that may help during damage analysis. 2. Identify the vehicle completely. Include VIN, year, make, model, engine, and optional equipment. 3. List mileage. 4. Identify and note all pre-collision damage. 5. Check wheels and tires, including the spare. Damaged wheels may provide clues about the collision 6. Confirm the point of impact and analyze how the damage has traveled.

   Inform students that unibody vehicles are a challenge to repair. This is because of the way the body reacts to collision forces. There are two types of damage that students must identify. They are direct (primary) damage and indirect (secondary) damage. Direct damage occurs in the area of immediate impact as a direct result of the vehicle striking an object. Direct damage is usually easy to locate and analyze. Indirect damage is caused by the shock of collision forces traveling through the body and inertial forces acting upon the rest of the unibody. Indirect damage can be more difficult to completely identify and analyze. It may be found anywhere on the vehicle. Before doing anything else, be sure to instruct student to take time to carefully perform an overall visual inspection and try to determine the direction of impact and the areas of indirect damage.

   Instruct student on what to look for when doing a vehicle inspection. The direction of impact will affect the parts damaged. If the vehicle was hit in the front, side, or rear, you will know to check specific areas and parts for damage. You should use a damage analysis checklist to make sure nothing is overlooked.

   Have students inspect the entire vehicle for damage, looking for: 1. Alignment of doors; 2. Alignment of the hood and deck lid; 3. Gaps between panels; 4. How the doors, hood, and deck lid open and close; 5. Ripples in the roof, fenders, or quarter panels away from the direct impact; 6. Cracked or stressed paint; 7. Cracked seam sealers; 8. Cracked or broken glass; 9. Smooth operation of windows; 10. Damage to interior (instrument panel, seats, seat belts, etc.), deployed air bag, stained carpet, and other problems; 11. Indications of previous damage; 12. Remove parts if needed to analyze hidden damage; 13. If it was a frontal collision, inspect parts in the engine compartment for damage; 14. Check under the vehicle for fluid leaks, which are signs of mechanical damage.

   1. The student should also note the angle of impact(s). 2. Mark areas of direct damage. 3. Note the indicators of indirect damage. 4. Note areas of pre-existing damage.

   Instruct students to always raise a badly damaged vehicle off the floor so that a good visual inspection can be made of all underbody and drivetrain parts. In some unibody vehicles, it might even be necessary to remove the drivetrain and suspension parts to make a thorough damage inspection.

   Instruct students that when creating a repair plan, be sure and list what repairs and replacements must be made. An example of a repair plan would be as follows: If the front grille and some of the related parts were damaged, the repairs or replacements needed would be listed as: Front Grille-Replace; Front Grille-Refinish; Opening Panel-Replace; Deflector (or Valance Panel)-Replace; Headlamp Door-Replace; Grille Opening Panel-Refinish.

   Inform students that the tech must find all damage, no matter how minor. After the student has found any obvious exterior damage, they must look for hidden damage. Instruct student that doors out of alignment and cracked stationary glass are often a solid clue to hidden damage to the frame or underbody structure. Be sure and instruct students to open the hood and check in the engine compartment for damage.



Refer to content

Evaluation and feedback Prior to Testing or Lab Work


Objective 1. / Formative assessment / Instructor will observe students as they practice the procedure to assure correct procedure and safety practices are being followed. A checklist will be utilized to chart student progress on the task. Questioning techniques will be utilized as necessary to demonstrate student comprehension / Adaptations and/or accommodations for special needs students will be added if required.

STUDENT ASSESSMENT: (Assess student progress with performance criteria.)


Objective 1 / Summative assessment / written test questions on stated objective / adaptation and / or accommodations for special needs students will be added if required

IMPACT--Reflection/Analysis of Teaching and Learning: (How did students’ progress in relation to the state objectives? Was the instruction successful? Analyze samples of student work particularly that which is unsatisfactory, for the purpose of planning further instruction.)

REFINEMENT--Lesson Extension and Follow-up: (To be filled in as the lesson is modified during initial planning and/or during the teaching learning process.)

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