Remove and replace motor vehicle body panels including permanently fixed panels

Business Sectors (Suites): Vehicle Body Repair
Developed by: IMI
Approved on: 30 Mar 2023


This standard is about removing a variety of exterior and sub-structure body panels and panel sections, including permanently fixed panels, where these are damaged and replaced with new or repaired replacements.

The ability to join vehicle panels by welding, bonding and mechanical fastening (alone and combined) is required.

Performance criteria

You must be able to:

P1 identify component materials involved in the construction of the vehicle in the areas that will be worked on during repair, prior to working on the vehicle 
P2 wear suitable personal protective equipment (PPE) throughout all vehicle body panel removal and replacement activities 
P3 inspect, prepare and use all the tools and equipment required, following manufacturers' instructions, prior to use 
P4 remove, replace and/or refit all necessary vehicle body panels and assemblies following: 

P4.1 the manufacturer's methods/instructions
P4.2 recognised researched repair methods
P4.3 your workplace procedures
P4.4 health, safety and legal requirements 
P5 promptly seek guidance from the relevant person(s) where there is the potential for your work to disturb other vehicle systems 
P6 use replacement body panels and assemblies which conform to the vehicle specifications for dimensions, materials and functional capability 
P7 use and apply sealants and weld primers and anti-corrosion treatments conforming to the material or vehicle manufacturer's specification 
P8 ensure all test weld pieces conform to the current British Standard for appearance and penetration 
P9 ensure permanently fixed panels are replaced without incurring damage to the vehicle systems 
P10 ensure all refitted body panels are aligned correctly with adjacent panels and fittings to manufacturers tolerances (panel gaps) 
P11 complete all removal and replacement activities within the agreed timescale 
P12 promptly report any anticipated delays in completion to the relevant person(s)

Knowledge and Understanding

You need to know and understand:

K1 the health and safety legislation and workplace procedures relevant to workshop practices, personal and vehicle protection when removing and replacing vehicle body panels 
K2 the dangers of cross contamination of material such as aluminium and steel 
K3 the requirements of manufacturer's warranty agreements 
K4 the vehicle work specification agreed 
K5 your workplace procedures for the referral of problems, reporting of delays to the completion of work and personal protection 
K6 the requirements for protecting the vehicle and contents from damage before, during and after removing and replacing vehicle body panels *
K7 the importance of working to agreed timescales and keeping others informed of progress 
K8 the relationship between time, cost and profitability 
K9 the importance of promptly reporting anticipated delays to the relevant person(s)  
K10 how to prepare, test and use the *tools and equipment required for the removal and replacement of vehicle body panels and ancillary fittings 
K11 how to operate resistance spot welding and metal inert gas (MIG), metal active gas (MAG) welding equipment to achieve welds to the current British Standard
K12 how to test Resistance Spot weld strength 
K13 how to carry out bonding/riveting cold repairs 
K14 the properties of component materials involved in the construction of the vehicle in the areas that will be worked on during repair 
K15 the properties of sealants, adhesives and anti-corrosion materials and the requirements for their safe use 
K16 the type of sealants and anti-corrosion materials to use and the manufacturer's recommended methods for their application and thickness 
K17 how to use adhesive bonding materials 
K18 how to select and apply sealants and anti-corrosion materials 
K19 the principles of chassis frame and monocoque vehicle construction 
K20 how to remove vehicle manufacturers original joining techniques 
K21 how to identify manufacturer's joining techniques and how they may differ to the repair method 
K22 the principles of thermal and non-thermal joining techniques ie spot welding, metal inert gas (MIG), metal active gas (MAG), bonding, hybrid joining etc 
K23 the different types of mechanical fixings for vehicle body panels and when and why they should be used
K24 the repair and welding implications of working with galvanised coatings, mild steels, HSS, UHSS and aluminium alloys 
K25 how panel removal and refitting affects the overall body structure of the vehicle 
K26 the causes and rectification of distortion resulting from welding
K27 how to find, interpret and use sources of information relevant to the removal and replacement of vehicle body panels and assemblies 
K28 how to remove and replace vehicle body panels and assemblies 
K29 how to remove and replace door skins 
K30 how to establish cut lines for partial panel replacement
K31 how to prepare all edges to be joined 
K32 how to select the correct joints and joining processes to match the repair area 
K33 the importance and implications of panel clamping and alignment to match existing contours and gaps 
K34 how to work safely avoiding damage to the vehicle and its systems
K35 the importance and implications of checking the accuracy of repair work 
K36 the types of quality control checks that can be used to ensure correct alignment and contour of panels and the operation of components to manufacturer's specification
K37 the methods of storing removed components and the importance of storing them correctly and in accordance with legal requirements  


All of the items listed below form part of this National Occupational Standard.

1. Body panels are: 

1.1. non-permanently fixed body panels 
1.2. welded exterior 
1.3. welded sub-structure panels (e.g. rear quarter panel, rear panel, roof, chassis legs, inner wheel housing, boot floors, complete sill, A post, B post, C post, D post and cross members) 
1.4. bonded panels (e.g. any panel that is fixed by adhesive bonding as part of the original manufacturer's process or approved repair process) 

2. Fitting methods are: 

2.1. welding 
2.2. mechanical fastening 
2.3. adhesive bonding 

3. Tools and Equipment are: 

3.1. workshop equipment 
3.2. generic hand tools 
3.3. manufacturer's specified and specialist tools 

Scope Performance

Scope Knowledge





Links To Other NOS

External Links

Version Number


Indicative Review Date

30 Mar 2026





Originating Organisation


Original URN


Relevant Occupations

Accident Repair Technicians, Body Repair and Alignment Technician (Automotive), Body Repair Technician (Automotive)

SOC Code



Remove; replace; motor; vehicle; body; panels; permanently fixed;