Removing, fitting and trimming bodywork to motorsport vehicles
Overview
This standard identifies the competences you need to carry out the removal, fitting and trimming of motorsport bodywork components, such as floor pans, door assemblies, bonnet assemblies, internal trim, rear wings, side pods, splitters and engine inlets, in accordance with approved procedures. It covers a range of motorsport vehicles such as single seater, rallying, sports cars, karts, historic and other specific approved competition vehicles.
The removing, fitting and trimming activities will include removing bodywork from the vehicle and storing it correctly, and making visual checks of the vehicle to determine its condition (such as damage or missing components). You will then be expected to dismantle bodywork to component level, remove existing fastenings, protect external surfaces from marking, scratching and damage, and to mark/label components to be stored. In refitting the bodywork, you will need to obtain all necessary new components and fastening devices, and to check them for suitability. Refitting will include trimming new bodywork to fit the vehicle, replacing all `lifed' items (such as quick release fastenings, threaded fasteners, rivets), replacing damaged/defective bodywork, re-assembling bodywork to sub-assembly level, setting, aligning and adjusting replaced bodywork, replacing relevant decals to match existing format, and polishing to the required specification.
On completion of the preparation activities, you will be required to carry out a range of checks, tests and adjustments, such as ensuring that the shut lines are uniform when attached to other bodywork and that any trimmed sections are in the correct position. You must ensure that all sharp edges have been removed, and that the bodywork is secure and free from foreign objects, dirt or other contamination. You will need to ensure that the vehicle has the correct visual appearance and that any decals continuing onto other parts of the bodywork are matched up.
Your responsibilities will require you to comply with organisational policy and procedures for the removal and fitting activities undertaken, and to report any problems with these activities that you cannot personally resolve, or that are outside your permitted authority, to the relevant people. You must ensure that all tools, equipment and materials used are correctly accounted for on completion of the activities, and that all necessary job/task documentation is completed accurately and legibly.
You will be expected to work as a member of a team, with minimal supervision, taking personal responsibility for your own actions and for the quality and accuracy of the work that you carry out. Where team working is involved, you must demonstrate a significant personal contribution during the team activities in order to satisfy the requirements of the standard, and competence in all the areas required by the standard must be demonstrated.
Your underpinning knowledge will provide a good understanding of your work, and will provide an informed approach to applying the appropriate removal and fitting techniques and procedures for bodywork on motorsport vehicles. You will understand the removal and fitting methods and procedures, and their application. You will know how the bodywork is fitted, the common problems that can occur, the purpose of the individual components and associated defects, in adequate depth to provide a sound basis for carrying out the preparation and fitting activities, correcting faults and ensuring that the bodywork is replaced to the required standard. You will also have sufficient knowledge of these components to ensure that they are fit for purpose and meet the specifications, thus providing a sound basis for carrying out the removal and fitting activities.
You will understand the safety precautions required when working on motorsport vehicles, especially those for isolating the equipment. You will be required to demonstrate safe working practices throughout, and will understand your responsibility for taking the necessary safeguards to protect yourself and others in the workplace.
Performance criteria
You must be able to:
- work safely at all times, complying with health and safety and other relevant regulations, directives and guidelines
- follow the relevant instructions, vehicle manuals and publications to carry out the required work
- remove and fit the components in their correct positions using appropriate methods and techniques
- take suitable precautions to prevent damage to components and the surrounding structure
- ensure that the removed components are clean and free from dirt, oil and debris, and that they are in a usable condition prior to being refitted and tested
- replace and secure the components, using the specified connectors and securing devices
- check that all operations have been completed and that the finished assembly meets the required specification
- label and store components that require repair or overhaul
- deal promptly and effectively with problems within your control and report those that cannot be solved
ensure that work records are completed, stored securely and available to others as per organisational requirements
leave the work area in a safe condition on completion of the activities, as per organisational and legal requirements
Knowledge and Understanding
You need to know and understand:
- the specific safety precautions to be taken whilst carrying out the activities (including any specific legislation, regulations or codes of practice relating to the activities, equipment or materials)
- the health and safety requirements of the work area and the activities, and the responsibility these requirements place on you
- the hazards associated with the activities, and how to minimise them and reduce risks
- the personal protective equipment and clothing (PPE) to be worn during the activities
- the procedures for obtaining the various types of manuals/drawing, job instructions and specifications that are used during the removal, fitting and trimming activities, and how to interpret them correctly.
- how to identify different types of bodywork on motorsport vehicles
- the removal, fitting and trimming methods and procedures to be used, and the importance of adhering to these
- how existing bodywork is to be removed and repaired or replaced, and the tools and equipment to be used
- the various mechanical fasteners and other components that are used (the use of threaded fasteners, rivets, adhesives, sealants and other specialised fasteners)
- the importance of using the specified fasteners for the removal, fitting and trimming, and why you must not use substitutes
- the use of torque wrenches, and the importance of ensuring that fasteners are adjusted to the required settings
- dealing with components or fastening devices that are incorrectly fitted, damaged or that have other faults
- the application of sealants and adhesives used during the removal, fitting and trimming activities, and the precautions to be taken when working with them
- the purpose and function of the various forms of bodywork used on motorsport vehicles
- the use of rivets (pop and solid), skin pins, quick release fasteners, and the importance of ensuring that they are used in the correct context
- the preparation to be undertaken on new components, prior to fitting them onto the motorsport vehicle
methods of fitting new bodywork panels, and methods of alignment to ensure correct skin lines (use of jigs)
how to conduct any necessary checks to ensure the accuracy and quality of the motorsport bodywork removal and fitting
- how to recognise defects (incorrect fitting and trimming, ineffective fasteners, component damage)
- the importance of ensuring that the completed assembly is free from foreign objects, dirt or other contamination
- the importance of ensuring that all sealants and lubricants used are of the correct specification for the vehicle
- how to check that the tools and equipment to be used are correctly calibrated, and are in a safe, tested and serviceable condition.
- the importance of ensuring that all tools are used correctly, checked and stored after use
- the problems with the removal and refitting operations, and the importance of informing appropriate people of non-conformances
- the recording documentation to be completed for the activities undertaken
- the procedure for the safe disposal of waste materials, scrap components, oils and fluids
- the extent of your own responsibility and to whom you should report if you have problems that you cannot resolve
- how to access, use and maintain information to comply with organisational requirements and legislation
Scope/range
Scope Performance
Carry out all of the following during the removal, fitting and trimming of the motorsport vehicle bodywork:
- plan the removal, fitting and trimming activities prior to beginning the work
- obtain and use the appropriate documentation (such as job instructions, trim assembly drawings, manuals, quality control documentation)
- adhere to procedures or systems in place for risk assessment, hazardous substances, personal protective equipment and other relevant safety regulations and procedures to realise a safe system of work
- provide safe access and working arrangements for the work area, and ensure that any appropriate environmental conditions can be met
- ensure that the work area is suitably prepared for the removal, fitting and trimming activities to take place
- obtain approval to carry out the removal and refitting activities
- position and secure the vehicle, using the correct equipment
- ensure that any required consumables are available
- leave the vehicle and work area in a safe condition, free from spillages and foreign object debris
- return all tools and equipment to the correct location on completion of the activities
Carry out the removal, fitting and trimming of bodywork on one of the following types of motorsport vehicle:
- single seater
- kart
- sports car
- rallying
- historic vehicle
- other specific approved competition vehicle
Use appropriate methods and techniques to remove, fit and trim motorsport bodywork, using fourteen of the following:
- making an initial judgment of the condition of the vehicle (such as damage, missing components)
- jigging components to ensure accuracy when replacing
- removing bodywork from the vehicle and storing it correctly
- replacing damaged/defective bodywork
- replacing all 'lifed' items (such as quick release fastenings, threaded fasteners, rivets)
- dismantling bodywork to component level
- removing existing fastenings
- trimming new bodywork to fit the vehicle, within specification
- disconnecting cables and connectors (where appropriate)
- re-assembling bodywork to sub-assembly level
- protecting external surfaces from marking, scratching and damage
- setting, aligning and adjusting replaced bodywork
- making mechanical connections
- marking/labelling of components
- making electrical connections (where appropriate)
- checking new components and fastenings for suitability
- pre-fitting fasteners and panels
- replacing relevant decals to match existing format
- polishing to the required specification
Use five of the following during the removal, fitting and trimming activities:
- jigs
- specialist tools
- alignment devices
- fixtures
- pneumatic tools
- respiratory protective equipment
- hand tools
- marking/measuring equipment
Prepare and fit six of the following motorsport vehicle bodywork components:
- floor pans
- fairings
- rear wings
- radiator inlets
- door assemblies
- seat assemblies
- side pods
- boot lid assemblies
- bonnet assemblies
- front wings
- splitters
- engine covers
- internal trim
- ducts
- engine inlets
- other specific bodywork
Carry out checks and adjustments on the fitted bodywork, to include six of the following:
- ensuring that shut lines are uniform when attached to other bodywork
- checking that any trimmed sections are in the correct position
- checking that any decals which continue onto other bodywork match
- ensuring that all sharp edges have been removed
- checking that the fitted bodywork is secure
- ensuring that the fitted bodywork is free from foreign objects, dirt or other contamination
- functional testing of rectified systems
- visual examinations to the required standard
- other specific tests
Check that removal, fitting and trimming of motorsport bodywork components complies with one of the following:
- race associations
- vehicle manufacturer's specification
- team/company standards and procedures
- specific vehicle requirements