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
    • Key Points: Aluminum file only to avoid contamination.
  1. Buffing
    • Key Points:
      • Only use 100 or 180 grit.
      • Then use 5inch round burgundy Scotch bright.
  1. Highlight Repair Area
    • Key Points:
      • Use blue highlight cloth.
      • Feel repair.
  1. Finish
    • Key Points:
      • 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
    • Key Points:
      • Ensure 80 grit pad is used.
  1. Stone/Highlight Repair Area
    • Key Points:
      • Gel Stone.
      • Use Blue highlight cloth.
  1. Finish
    • Key Points:
      • 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
    • Key Points:
      • Opposite direction of file.
  1. Highlight Repair Area
    • Key Points:
      • In both directions.
      • Use blue highlight cloth.
  1. Buffing
    • Key Points:
      • Only use 80 grit.
  1. Finish
    • Key Points:
      • 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
    • Key Points:
      • Use proper grit sandpaper depending on program.
  1. Validate
    • Key Points:
      • Use highlight or stone to ensure no defects. Proper tools depending on program.
  1. Finish
    • Key Points:
      • 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)
    • Key Points:
      • Check certification level.
      • Cross-check for localization.
  1. Open Rack
    • Key Points:
      • Reference Unit Load.
  1. Pick Part
    • Key Points:
      • Always use hands.
      • Body sides can be slid on floor.
  1. Set Part
    • Key Points:
      • Ensure part is in a good position to work.
  1. Rework Part
    • Key Points:
      • Follow repair procedure.
  1. Pick Part
    • Key Points:
      • Always use hands.
      • Body sides can be slid on floor.
  1. Set Back in Rack
    • Key Points:
      • Ensure all spots are filled.
  1. Tag Rack
    • Key Points:
      • Leave a tag to the rack.
      • Ensure grade has been made over the rack.
  1. TLCQQ (Traceability, Legibility, Cleanliness, Quantity, Quality)
    • Key Points:
      • 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
    • Key Points:
      • Fore-Aft.
      • Clean stone.
  1. Highlight Part
    • Key Points:
      • Clean cloth.
      • Both directions.
  1. File
    • Key Points:
      • File until flat.
  1. Buffing
    • Key Points:
      • 80 Grit – Metallic Product.
      • 100 Grit – Finish Doors.
      • 120 Grit – Cotton, Scotch Brite – Aluminum.
  1. Wipe Dust Off
    • Key Points:
      • Clean rag.
  1. Repeat Step 1 & 2
    • Key Points:
      • Ensure defect has been properly reworked.
      • Stone, Highlight, Feel.
  1. Verify
    • Key Points:
      • 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
    • Key Points:
      • Fore-Aft.
      • Clean stone.
  1. Highlight Defect
    • Key Points:
      • Clean cloth.
      • Fore-Aft.
  1. Pick Up with Slapper and Body Hammer
    • Key Points:
      • Use pick end of hammer.
      • Guide with thumb.
      • Shape topper by tapping top of part.
  1. File
    • Key Points:
      • File until flat.
  1. Buffing
    • Key Points:
      • Buff until file scratch removed.
  1. Repeat Step 1 & 2
    • Key Points:
      • Ensure defect has been properly reworked.
      • Stone, Highlight, Feel.
  1. Verify
    • Key Points:
      • 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
    • Key Points:
      • Fore-Aft.
      • Clean stone.
  1. Highlight Defect
    • Key Points:
      • Clean cloth.
      • Fore-Aft.
  1. Distinguish Repair Procedure
    • Key Points:
      • Just buff.
      • Quick Repair Method.
  1. File
    • Key Points:
      • File until flat.
  1. Buffing
    • Key Points:
      • Buff until file scratch removed.
  1. Repeat Step 1 & 2
    • Key Points:
      • Repeat steps 1&2 to ensure quality.
      • Rework may not be 100% flat after repair.
  1. Verify
    • Key Points:
      • 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
    • Key Points:
      • Fore-Aft.
      • Clean stone.
  1. Highlight Defect
    • Key Points:
      • Clean cloth.
      • Fore-Aft.
  1. Pick Up with Slapper and Body Hammer
    • Key Points:
      • Use pick end of hammer.
      • Guide with thumb.
      • Shape topper by tapping top of part.
  1. File
    • Key Points:
      • File until flat.
  1. Buffing
    • Key Points:
      • Buff until file scratch removed.
  1. Repeat Step 1 & 2
    • Key Points:
      • Repeat steps 1&2 to ensure quality.
      • Rework may not be 100% flat after repair.
  1. Verify
    • Key Points:
      • 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
    • Key Points:
      • Fore-Aft.
      • Clean stone.
  1. Highlight Part
    • Key Points:
      • Clean cloth.
      • Both directions.
  1. File
    • Key Points:
      • File until flat.
  1. Pick Up & File Out
    • Key Points:
      • Use body hammer (pick end) & slapper to bring metal flush.
      • File until flat.
  1. Buffing
    • Key Points:
      • Buff until file scratch removed.
  1. Repeat Step 1 & 2
    • Key Points:
      • Repeat steps 1&2 to ensure quality.
      • Rework may not be 100% flat after repair.
  1. Verify
    • Key Points:
      • 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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About the Author: Bernard Aybout

In the land of bytes and bits, a father of three sits, With a heart for tech and coding kits, in IT he never quits. At Magna's door, he took his stance, in Canada's wide expanse, At Karmax Heavy Stamping - Cosma's dance, he gave his career a chance. With a passion deep for teaching code, to the young minds he showed, The path where digital seeds are sowed, in critical thinking mode. But alas, not all was bright and fair, at Magna's lair, oh despair, Harassment, intimidation, a chilling air, made the workplace hard to bear. Management's maze and morale's dip, made our hero's spirit flip, In a demoralizing grip, his well-being began to slip. So he bid adieu to Magna's scene, from the division not so serene, Yet in tech, his interest keen, continues to inspire and convene.