Comprehensive Guide to Precision Metal Finishing Techniques – Two to your one, all day, everyday.

Comprehensive Guide to Precision Metal Finishing Techniques – Two to your one, all day, everyday.   :-)

Metal Finishing Procedure for JL/JT Aluminum Class A Parts

Job: JL/JT Aluminum Class A Parts
Reference: 10AQP Metal Finish/Teardown Job Elements
Customer: FCA
Product: Aluminum Class A
Program: JL/JT
Vehicle: Wrangler & Gladiator
Release Date: 14-Dec-20

Important Steps

1. File Part

1. • Key Points: Aluminum file only to avoid contamination.

1. Buffing

1. • Key Points:

1. • • Only use 100 or 180 grit.
     • Then use 5inch round burgundy Scotch bright.

1. Highlight Repair Area

1. • Key Points:

1. • • Use blue highlight cloth.
     • Feel repair.

1. Finish

1. • Key Points:

1. • • Wipe clean with tack rag/cheese cloth to achieve a dust/grind debris free finish.

Safety

• Eye Protection
• Hearing Protection
• Foot Protection
• Hand Protection
• Arm Protection
• Head/Face Protection

Visual Aids

• Images of tools and materials needed for each step.
• Pictures of the correct finish and the vehicles concerned.

Note: Ensure a mask is worn at all times.

Metal Finishing Procedure for D2UC Roofs

Job: D2UC Roofs
Reference: 10AQP Metal Finish/Teardown Job Elements
Customer: GM
Product: Roofs
Program: D2UC CAMI
Vehicle: Equinox
Release Date: 14-Dec-20

Important Steps

1. Buffing

1. • Key Points:

1. • • Ensure 80 grit pad is used.

1. Stone/Highlight Repair Area

1. • Key Points:

1. • • Gel Stone.
     • Use Blue highlight cloth.

1. Finish

1. • Key Points:

1. • • Ensure a 3M P500 grit square is used to feather the edges.

Safety

• Eye Protection
• Hearing Protection
• Foot Protection
• Hand Protection
• Arm Protection
• Head/Face Protection

Visual Aids

• Images showing the correct use of tools and examples of acceptable and unacceptable finishes.

Metal Finishing Procedure for JK Hood

Job: JK Hood
Reference: 10AQP Metal Finish/Teardown Job Elements
Customer: FCA
Product: Hood
Program: JK
Vehicle: Wrangler
Release Date: 14-Dec-20

Important Steps

1. Stone

1. • Key Points:

1. • • Opposite direction of file.

1. Highlight Repair Area

1. • Key Points:

1. • • In both directions.
     • Use blue highlight cloth.

1. Buffing

1. • Key Points:

1. • • Only use 80 grit.

1. Finish

1. • Key Points:

1. • • Apply Chemet/Rust inhibitor to finished repair.

Safety

• Eye Protection
• Hearing Protection
• Foot Protection
• Hand Protection
• Arm Protection
• Head/Face Protection

Visual Aids

• Images of correct buffing technique and final appearance of a properly finished hood.

Metal Finishing Procedure for Service Parts (All Models & Programs)

Job: Service Parts (All Models & Programs)
Reference: 10AQP Metal Finish/Teardown Job Elements
Customer: FCA
Product: All
Program: All
Vehicle: All
Release Date: 14-Dec-20

Important Steps

1. Buffing

1. • Key Points:

1. • • Use proper grit sandpaper depending on program.

1. Validate

1. • Key Points:

1. • • Use highlight or stone to ensure no defects. Proper tools depending on program.

1. Finish

1. • Key Points:

1. • • Apply Chemet/Rust inhibitor to finished repair.

Safety

• Eye Protection
• Hearing Protection
• Foot Protection
• Hand Protection
• Arm Protection
• Head/Face Protection

Visual Aids

• Images of various service parts, tools, and the correct finish.

Metal Finishing Procedure for General Rework

Job: General Rework
Reference: 10AQP Metal Finish/Teardown Job Elements
Release Date: 29-Aug-19

Important Steps

1. Locate DMR (Defective Material Report)

1. • Key Points:

1. • • Check certification level.
     • Cross-check for localization.

1. Open Rack

1. • Key Points:

1. • • Reference Unit Load.

1. Pick Part

1. • Key Points:

1. • • Always use hands.
     • Body sides can be slid on floor.

1. Set Part

1. • Key Points:

1. • • Ensure part is in a good position to work.

1. Rework Part

1. • Key Points:

1. • • Follow repair procedure.

1. Pick Part

1. • Key Points:

1. • • Always use hands.
     • Body sides can be slid on floor.

1. Set Back in Rack

1. • Key Points:

1. • • Ensure all spots are filled.

1. Tag Rack

1. • Key Points:

1. • • Leave a tag to the rack.
     • Ensure grade has been made over the rack.

1. TLCQQ (Traceability, Legibility, Cleanliness, Quantity, Quality)

1. • Key Points:

1. • • Initial reworked part.
     • Have another team member grade and review part.

Safety

• Eye Protection
• Hearing Protection
• Foot Protection
• Hand Protection
• Arm Protection
• Head/Face Protection

Visual Aids

• Step-by-step photographs of the rework process.

Metal Finishing Procedure for High Spot Minor

Job: High Spot Minor
Reference: 10AQP Metal Finish/Teardown Job Elements
Release Date: 18-Nov-20

Important Steps

1. Stone Part

1. • Key Points:

1. • • Fore-Aft.
     • Clean stone.

1. Highlight Part

1. • Key Points:

1. • • Clean cloth.
     • Both directions.

1. File

1. • Key Points:

1. • • File until flat.

1. Buffing

1. • Key Points:

1. • • 80 Grit – Metallic Product.
     • 100 Grit – Finish Doors.
     • 120 Grit – Cotton, Scotch Brite – Aluminum.

1. Wipe Dust Off

1. • Key Points:

1. • • Clean rag.

1. Repeat Step 1 & 2

1. • Key Points:

1. • • Ensure defect has been properly reworked.
     • Stone, Highlight, Feel.

1. Verify

1. • Key Points:

1. • • Hold at an angle towards light.

Safety

• Eye Protection
• Hearing Protection
• Foot Protection
• Hand Protection
• Arm Protection
• Head/Face Protection

Visual Aids

• Photographs demonstrating the proper techniques for each step and examples of the final finish.

Metal Finishing Procedure for High Spot Major

Job: High Spot Major
Reference: 10AQP Metal Finish/Teardown Job Elements
Release Date: 18-Nov-20

Important Steps

1. Stone Part

1. • Key Points:

1. • • Fore-Aft.
     • Clean stone.

1. Highlight Defect

1. • Key Points:

1. • • Clean cloth.
     • Fore-Aft.

1. Pick Up with Slapper and Body Hammer

1. • Key Points:

1. • • Use pick end of hammer.
     • Guide with thumb.
     • Shape topper by tapping top of part.

1. File

1. • Key Points:

1. • • File until flat.

1. Buffing

1. • Key Points:

1. • • Buff until file scratch removed.

1. Repeat Step 1 & 2

1. • Key Points:

1. • • Ensure defect has been properly reworked.
     • Stone, Highlight, Feel.

1. Verify

1. • Key Points:

1. • • Hold at an angle towards light.

Safety

• Eye Protection
• Hearing Protection
• Foot Protection
• Hand Protection
• Arm Protection
• Head/Face Protection

Visual Aids

• Images showing the correct hammering, filing, and buffing techniques, as well as the ideal finished result.

Metal Finishing Procedure for Hit Mark Minor

Job: Hit Mark Minor
Reference: 10AQP Metal Finish/Teardown Job Elements
Release Date: 29-Aug-19

Important Steps

1. Stone Part

1. • Key Points:

1. • • Fore-Aft.
     • Clean stone.

1. Highlight Defect

1. • Key Points:

1. • • Clean cloth.
     • Fore-Aft.

1. Distinguish Repair Procedure

1. • Key Points:

1. • • Just buff.
     • Quick Repair Method.

1. File

1. • Key Points:

1. • • File until flat.

1. Buffing

1. • Key Points:

1. • • Buff until file scratch removed.

1. Repeat Step 1 & 2

1. • Key Points:

1. • • Repeat steps 1&2 to ensure quality.
     • Rework may not be 100% flat after repair.

1. Verify

1. • Key Points:

1. • • Hold at an angle towards light.

Safety

• Eye Protection
• Hearing Protection
• Foot Protection
• Hand Protection
• Arm Protection
• Head/Face Protection

Metal Finishing Procedure for Hit Mark Major

Job: Hit Mark Major
Reference: 10AQP Metal Finish/Teardown Job Elements
Release Date: 29-Aug-19

Important Steps

1. Stone Part

1. • Key Points:

1. • • Fore-Aft.
     • Clean stone.

1. Highlight Defect

1. • Key Points:

1. • • Clean cloth.
     • Fore-Aft.

1. Pick Up with Slapper and Body Hammer

1. • Key Points:

1. • • Use pick end of hammer.
     • Guide with thumb.
     • Shape topper by tapping top of part.

1. File

1. • Key Points:

1. • • File until flat.

1. Buffing

1. • Key Points:

1. • • Buff until file scratch removed.

1. Repeat Step 1 & 2

1. • Key Points:

1. • • Repeat steps 1&2 to ensure quality.
     • Rework may not be 100% flat after repair.

1. Verify

1. • Key Points:

1. • • Hold at an angle towards light.

Safety

• Eye Protection
• Hearing Protection
• Foot Protection
• Hand Protection
• Arm Protection
• Head/Face Protection

Metal Finishing Procedure for Low Spot Minor

Job: Low Spot Minor
Reference: 10AQP Metal Finish/Teardown Job Elements
Release Date: 29-Aug-19

Important Steps

1. Stone Part

1. • Key Points:

1. • • Fore-Aft.
     • Clean stone.

1. Highlight Part

1. • Key Points:

1. • • Clean cloth.
     • Both directions.

1. File

1. • Key Points:

1. • • File until flat.

1. Pick Up & File Out

1. • Key Points:

1. • • Use body hammer (pick end) & slapper to bring metal flush.
     • File until flat.

1. Buffing

1. • Key Points:

1. • • Buff until file scratch removed.

1. Repeat Step 1 & 2

1. • Key Points:

1. • • Repeat steps 1&2 to ensure quality.
     • Rework may not be 100% flat after repair.

1. Verify

1. • Key Points:

1. • • Hold at an angle towards light.

Safety

• Eye Protection
• Hearing Protection
• Foot Protection
• Hand Protection
• Arm Protection
• Head/Face Protection

Visual Aids

• Photographs demonstrating the appropriate methods for addressing minor low spots on metal surfaces.

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