LV04 - Vehicle Construction - Issue 1 PDF

kap all covers 6/9/03 9:48 am Page 7
Student Workbook
LV04
Vehicle
Construction
(1)
LV04/SWB
Student Workbook for Technical Certificates in
Light Vehicle Maintenance and Repair
MODULE LV04
VEHICLE CONSTRUCTION
Contents
Page Page
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Materials Used in Vehicle Hinges 22
Construction: 3 Door lock mechanism 23
Main categories of materials Weather seals 23
used in automotive construction 3 Progress check 2 24
Metals 3
Ferrous metals 4 Vehicle Chassis Types: 25
High strength steel plate 4 Chassis construction 26
Cast iron 4 Self supporting frame 26
Non–ferrous metals 4 Partly supporting frame (sub-frame) 27
Copper 4 Platform chassis 27
Tin 5 Backbone chassis 28
Lead 5 Composite body 28
Aluminium 5 Ladder frame 29
Other materials (non-metallic) 6 Monocoque body 29
Plastics 6 Space frame 30
Rubber 7 Progress check 3 31
Totally tempered glass 7
Partly tempered glass 8 Chassis Construction Sub-
Laminated glass 8 assemblies: 32
Kevlar 9 Box section 32
Progress check 1 10 Tubular section (space frame) 33
C shaped channel 33
Component Identification: 11 Load bearing points 34
Exercise 1 12 Progress check 4 35
Spoilers and air dams 12
Sub frames 13 Vehicle Safety Construction
Roof panel 13 Features: 36
Scuttle plate 14 Passive systems 36
Side structure 14 Crumple zones 36
Exercise 2 15 Side impact 37
Exercise 3 16 SRS airbag 38
Panel fixing 17
Locking and securing devices 18 (Cont.)
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Copyright © Automotive Skills Limited 2003 LV04: Vehicle Construction Issue 1
All Rights Reserved
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Page ………
Seat belt pre-tensioners 38

Energy absorbing steering column 39
Active systems 40
ABS (Anti-lock Braking System) 40
VSC (Vehicle Stability Control) 40
Progress check 5 41
Body Deformation and the Ripple

Effect: 42
Benefits of safety systems 43
Regulations 43
Progress check 6 44
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Materials Used in Vehicle Construction
Main categories of materials used in automotive construction
The modern motor vehicle uses a vast array of differing materials in its
construction, each material adding to the vehicle’s strength, reliability,
resistance to corrosion and low noise vibration and harshness (NVH).
Manufacturers of motor vehicles now have to consider the impact that the use
of such materials will have on the environment.
Metals
Metals form the major make up of a vehicle’s construction. The properties

that metals possess lend themselves particularly well to use as a constructive
material for vehicles. Metals have the following properties:
• ductility – can be drawn into wire
• malleability – can be rolled and hammered into sheets and foil
• large specific gravity (dense)
• high in electrical and thermal conductivity.
It should be noted that mercury is a metal but possesses few of the above
properties.
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Ferrous metals
A ferrous metal is one that is derived from iron. Iron is seldom used in its pure
form, as it possesses poor strength and durability (it’s quite brittle). To
improve its characteristics, iron is often mixed with carbon. The amount of
carbon that is used has a huge effect on the material. If we use between
0.035% and 2% carbon, we have just produced steel. If we use between 2%
and 6.67% we have just produced cast iron.
Carbon steel is used for body panels and some suspension components on
motor vehicles.
High strength steel plate
High strength steel plate can be created by mixing carbon steel with other
materials, or through special heat-treating processes. Mixing in silicon,
manganese, phosphorous, titanium, vanadium or chromium can vastly
increase the strength of the steel and allow a manufacturer to reduce the
thickness of the material for a given required strength. This reduces cost and
saves weight, improving performance all-round. Heating steel to specific
temperatures and then cooling them rapidly (known as quenching) can also
achieve considerable changes in steels properties.
Cast iron
Cast iron (iron containing 2% carbon or more) is often used for engine
components and is hot cast into moulds as a liquid. Cast iron has good wear
characteristics but is brittle.
Non-ferrous metals
Non-ferrous metals are metals that contain no iron. Some examples that are
used in the construction of vehicles are:
Copper
Copper has very high electrical and thermal conductivity properties. Copper is
used in the electrical harnesses and cooling systems pipe work on vehicles.
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Tin
Tin is used to a limited degree in vehicle construction, as it is prone to

corrosion. It is alloyed with lead to produce solder that is used in the joining of
electrical circuits on vehicles. An interesting fact is that solder has a lower
melting point than both of its constituent alloy materials (lead and tin).
Lead
Lead is used in the construction of vehicle batteries and is also used in the
alloyed metal of crank shaft bearings.
Aluminium
Aluminium, as well as being the most abundant metal (and therefore cheap) is
extremely light and has good electrical conductivity. It is used extensively on
vehicles often making up large proportions of engine components and even
body panels and structural members. As can be seen from the table above,
aluminium can be alloyed with many different materials to give it specific
characteristics.
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Other materials (non-metallic)
Non-metallic materials are used in abundance on modern motor vehicles.

They fall into two main categories – organic (natural) and inorganic. Organic
materials would include leather (seat covers etc.) and plastics (derived from
oil) and inorganic would include glass.
Plastics
A selection of plastics that are regularly used in the construction of motor

vehicles are shown above.
Plastics are classified as either thermoplastics or thermosetting plastics. A

thermoplastic is one that becomes pliable again when reheated, a
thermosetting plastic, once initially set, cannot be reheated (they burn rather
than melt).
Be aware that ECU casings are often made of ABS and this can be
misleading if you are trying to identify the ABS ECU (Anti-lock Braking
System) as ABS is often stamped on these assemblies to identify the material
not the function!
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Rubber
Rubber can be either natural or synthetic (man made). Natural rubber is

made from the sap of a rubber tree. In its natural state it is of little use, but
once vulcanised – heated with sulphur – it takes on elastic properties (the
ability to readopt original shape once a deflecting force is removed).
Synthetic rubber is an elastic polymer and tends to be far more suited to

vehicle applications. Chemical engineers can change its structure to ensure
compatibility with highly aggressive oils such as brake fluid.
Totally tempered glass
Totally tempered glass is heat-treated in accordance with the diagram above.

When you heat a given material you change its molecular structure physically.
Most materials if allowed to cool slowly will readopt their original molecular
condition but if you quench that material (rapidly cool it) it will stick in that
changed state. This is often a highly stressed state. Glass is no exception.
Totally tempered glass is cooled rapidly at the end of the process to retain
strength-orientated characteristics. Quenching rapidly makes the glass
around four times more shock resistant than conventional glass. However, if it
does break it often shatters catastrophically because of the quenching
stresses within it depriving the driver of any forward vision. For this reason it
is seldom used for front screens.
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Partly tempered glass
Glass that is partly tempered receives limited quenching to the middle area.
This process ensures that if breakage occurs the glass that has only been
partly tempered breaks into very large pieces Therefore a limited amount of
frontal vision is retained.
Laminated glass
To laminate means to layer. Laminated glass is two thin sheets of glass

bonded together with a transparent resin film. As a safety glass it has huge
benefits.
The resin layer prevents the glass shards from falling into the vehicle when
the screen breaks. It is highly resistant to penetration and frontal view is
maintained upon breakage.
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Kevlar
Kevlar is a manmade organic fibre introduced in the early 1970’s. It combines

high tensile strength with low weight and has high chemical resistance. It is
tough, with high cut resistance and is also flame proof and self-extinguishing.
Typical applications:
• bullet proof vests
• helmets
• Formula 1 racing car bodies
• aircraft bodies
• brake pads and clutch linings
• tyres
• gaskets
• transmission belts
• hoses
• data transmission cables
• vehicle body panels.
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Progress check 1
Answer the following questions:
1. What are the minimum and maximum carbon content values for iron to
be classed as steel?
2. In the context of plastics, what does ABS stand for?
3. What does synthetic mean?
4. List five applications for Kelvar on a motor vehicle
5. What does the term laminated refer to when used in conjunction with
vehicle windscreens?
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Component Identification
Doors, bonnet and boot lid
It is important to understand that all component parts that go up to make a

vehicle’s body have specific names. However, different countries often use
different names. Typical!
A wing can also be a fender; a doorsill a rocker cover, a bonnet could be

referred to as a hood.
Today's vehicles evolved from early forms of transport and as such retain a
certain amount of the terminology from these periods. For example, a ‘list rail’
is a term used to describe a supporting piece stretching from one side of a
structure to the other (such as the boat lists to port or starboard). A term
derived from our naval heritage.
A ‘cant rail’ is a name given to a strengthening structure running from front to

rear.
A ‘flitch plate’ is a strengthening plate inside a beam.
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Exercise 1
Label the key components on the diagram below:
Spoilers and air dams
The front air dam and rear spoiler help to stabilise the vehicle and give better
fuel economy through improved airflow over the body. Some spoilers can
actually create a positive pressure above the assembly, resulting in
considerable down force and vastly improved performance all round.
However, this is most unusual for a road car – at best the spoiler reduces lift
at high speed, at worst there are no benefits whatsoever rather than the
enhancement of appeal to some drivers!
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Sub-frames
A sub-frame is often used to mount the major assemblies on a vehicle

equipped with a monocoque type chassis configuration.
Roof panel
The roof panel is a major structural member, experiencing considerable

compressive forces. If the vehicle has a factory fitted sunroof, the roof panel
is often strengthened to accommodate the loss of strength that this item would
create.
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Scuttle plate
The scuttle plate used to form part of the integral structural strength of a
vehicle’s chassis, but designs have altered considerably over the last few
years and the importance of the scuttle has diminished. It is now more often a
trim panel or at most a mounting for the wiper linkage.
Side structure
The side of the vehicle generates a good deal of the structural integrity of a
vehicle’s chassis. The major components that go to make up the structure
can be seen in the figure above.
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Exercise 2
Working directly on the picture below, assign the correct letters to the
component names in the list below:
• chassis leg
• boot floor
• boot floor side extension.
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Exercise 3
Complete the list of component names working directly from the diagram ( 2
have been done for you)
G Front door
K Front wing
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Panel fixing
Many different methods are employed to fix panels to a vehicles chassis.

Below are a few examples:
• bolt
• speed clip and speed bolt
• hinge, bolted
• hinge, pinned
• locks
• weather seals
• fasteners
• welding.
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Locking and securing devices
Screw Hex screw

Bolt
Coach bolt
Self tapping
Countersunk screw
There are many different types of locking device available, some of which are
pictured here. They are all designed with one primary task in mind – holding
components together, either permanently or temporarily. A common
misconception is that a screw has a sharp point and is designed to cut its own
thread. This is not correct in engineering terms. A screw is almost identical to
a bolt with the exception that it is threaded all the way to the bottom of the
head and is seldom used in conjunction with a nut (it screws into threaded
components). A bolt has a thread-less shank. Only self-tapping screws (cut
their own thread) have sharp points!
Hexagon head bolts and screws are used far less frequently now than was the
case only a few years ago. You are far more likely to come across multi-
spline types and Torx types where a securing device needs to be
accommodated in a tight space (with hexagon head devices, space needs to
be left around the head to accommodate a socket for the fitting and removal).
Tight spaces are now commonplace on light vehicles as manufacturers strive
for every gram of weight saving and every centimetre of extra occupancy
space.
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When ordering a bolt (standard design) from the parts department, they will
want to know the following information if the device you want is not specific to
task:
• overall length
• diameter
• thread pitch
• strength rating.
A typical specification could be:
• 75mm long, M8 coarse thread, strength rating 8.
This would give you a bolt that is 75mm in length from its threaded end to the
underneath of the head, an 8 mm thread diameter with a thread pitch of
1.5mm with a strength rating that would see it safe up to a torque of 13Nm.
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Nut Flanged nut Nylock nut
Castellated nut Wing nut Shear nut
Nuts are also available in several different types. When ordering you must
ensure that you ask for a nut that has the same thread as the bolt to which it is
to be fitted – this means both thread diameter and thread pitch. Do you want
metric fine (1.25mm pitch) or metric coarse (1.5mm pitch)? Some specialist
nuts can be seen above. The flanged nut is designed to spread the
compression load a little onto the component surface. The Nylock nut (trade
name) is designed to grip the bolt thread through means of friction, generated
by the bolts thread cutting through the nylon collar at the top of the nut. It
should be noted that these nuts should never be reused. Castellated nuts are
designed to be used in conjunction with split pins, and wing nuts are used
where regular and easy removal is required (seldom used on modern
vehicles). Shear nuts are often the choice where security is an issue such as
with vehicle immobiliser equipment.
Flat washer
Penny washer
Spring washer
Washers are used to spread load and often to reduce the possibility of the bolt
shaking loose through vibration.
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There are now many different types of chemical compounds available to do
anything from locking a thread to prevent vibration loosening, to sealing joints
and even temporarily sealing radiators, tyres and cylinder blocks!
Always read the instructions thoroughly before use and if you are unsure of
the health and safety risks, always refer to the COSHH data sheet for that
specific product.
Some panels are bonded into place and others (like rear masking panels) can
be riveted. Masking panels are found under the rear light units and sit on top
of rear bumper. Not all parts, like front wings are bolted into place they are
also welded. Trims are held in place with plastic clips or screws. Mouldings
that go down the side of vehicles can be held with plastic clips or double sided
tape.
MIG Welder Spot Welder
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A spot welder is generally used but where space or access is limited or for
welding panels such as chassis legs that need a seam weld a MIG welder is
preferred.
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Riveting: This kind of panel fixing is used on some steel vehicles but only a
small amount. It is used on a larger scale on aluminium vehicles to fix panels
together. Bonding of panels is also used on aluminium vehicles and
composite cars and will be used to a greater extent in vehicle production in
the future.
Hinges
Hinges are often bolted or pinned to the vehicles chassis. Pins are passed
through a locating hole in the hinge, the hinge itself being welded to the body.
The hinge is in two parts - upper and lower; on the door there is one locating
hinge that fixes to the hinge on the body. The pin is then inserted into the
hole going through all three parts of the hinge thus fixing the door to vehicle.
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Door lock mechanism
Door lock mechanisms differ greatly in design between manufacturers, but a

typical layout can be seen here. The hook (mounted on the door) when
engaged with the striker (on the ‘B’ post) secures the door in the closed
position. The hook is rotated out of engagement with the striker, through
movement of the ratchet mechanism, via the door handle.
Weather seals
Weather seals are used in a variety of places on a vehicle - in door shuts, sun
roofs, door frames and scuttle cowls to name but a few.
Many different cross-sectional shapes are available to realise good sealing

properties across the broad range of applications.
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Progress check 2
1. What do other countries sometimes call a bonnet?
2. What is the fixing device pictured called?
3. What is the purpose of a spoiler?
4. If a vehicle is leaking water from around the windscreen what is the

most likely component that to have failed?
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Vehicle Chassis Types
Vehicles have evolved from their early forms to those we have today; a
multitude of differing body styles and construction techniques are employed in
building them.
Label the following body styles with the correct name:
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Chassis construction
Many different types of chassis construction methods have developed over

the years. Whichever type is used, it is important that the structure provides a
good deal of stiffness (to prevent handling anomalies) and general strength. It
must also minimally intrude on occupancy space and be a cost effective
method under mass production conditions. Safety in the event of a collision is
also of primary importance, and increasingly, we are seeing emphasis placed
on the ability to recycle the materials used in construction when the vehicle
reaches the end of its useable life.
A manufacturer will take these factors into account when considering their
choice of chassis construction method for a given model, and will often
choose a method that lends itself most favourably to the type of vehicle they
are looking to build. For example, if the model were aimed at large volume
sales, cost effective production suitability would be of primary importance and
perhaps chassis stiffness less so.
Self supporting frame
This type of chassis is used on 4 wheel vehicles like Toyota Land Cruisers,
Land Rovers and other off road vehicles. The body is mounted to the chassis
on rubber bushes and the two bolted together.
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Partly supporting frame (sub-frame)
This kind of frame was used on Minis and on older Renault models. It is also
often referred to as a sub-frame. It is mounted on to the body and the engine
and suspension are fixed to the sub frame. On some vehicles there are front
and rear sub-frames.
Platform chassis
Volkswagen, Citroen and Renault used this method. The floor pan has the
mechanical parts attached to it and the engine, transmission, steering
mechanism and suspension is bolted to the platform.
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Backbone chassis
This type of frame acts as a skeletal spine and is shaped like a single tunnel.
The body is bolted directly to this spine.
Composite body
A composite designed vehicle is a chassis with a fibreglass or carbon fibre

body that is secured to the chassis frame. Carbon fibre is very strong and
extremely light weight.
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Ladder frame
The ladder frame is made of two parallel side members that are joined by a
number of cross members. It is commonly used on load carrying vehicles and
light commercials.
Monocoque body
The monocoque body is a design concept that traces its origins to aircraft.
The body is light yet has enough strength to withstand bends and twists due
to its integrated construction. It is constructed with a combination of thin steel
panels pressed into various shapes and spot welded together. Due to the
combination of various panels pressed into complex shapes, once damaged
the monocoque body requires extra time to repair.
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Space frame
A skeletal structure formed from sections of steel pipe. It is very costly to

produce and therefore rarely used.
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Progress check 3
1. What is the difference between a self-supporting frame and a

monocoque chassis construction?
2. Name one advantage of carbon composite chassis construction:
3. Why do certain structural members have to be strengthened on a

cabriolet-bodied vehicle?
4. What is the most common type of chassis used on commercial

vehicles?
5. List two advantages of monocque construction:
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Chassis Construction Sub-Assemblies
We have seen that there are numerous different chassis construction
arrangements from which manufacturers can choose. Most of these methods
employ the use of pre-fabricated sub-assemblies. These can consist of the
following:
• box section
• tubular section
• channel.
Box section
The box section is made up of two C shaped channels combined. These are
off-centred vertically and laterally and welded together to form the box section.
This section has very high levels of stiffness but does tend to be relatively
heavy. 4 wheel drive vehicles favour this design due to the expected rigours
of off-road driving and the flex that this creates in chassis members.
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Tubular section (space frame)
Constructed of steel pipe welded together to form a skeleton. As the chassis

and body are constructed of steel pipe it is not exactly an independent type
frame. Racing cars often use this type of construction.
C shaped channel
This is used on ladder frame chassis arrangements found on light and heavy
commercial vehicles.
Its properties include good stiffness and low cost. The open channel section
also provides extra space for the mounting of components.
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Load bearing points
Areas marked in grey are some of the areas on a monocoque body that are
load bearing members and load bearing points.
These areas provide the majority of the overall strength of the chassis in
respect of driving, braking and cornering forces and also during accidents.
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Progress check 4
1. Name one load bearing point on a monocoque chassis:
2. What type of vehicle often uses a ladder frame chassis construction?
3. How is a ‘list rail’ positioned on a chassis?
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Vehicle Safety Construction Features
Modern vehicles have many safety features ’built in’ from the design stage.
Some of these systems and features are more visible than others (such as
airbags) and some less so - such as collapsible steering columns and crumple
zones.
All vehicle safety features and systems are classified as either ‘passive’ or
‘active’.
A passive safety system is one that acts to limit injury during an accident.
An active safety system is one that acts to prevent the accident from
happening in the first place.
Passive systems
The following are examples of passive vehicle safety systems:
• crumple zones
• side impact protection air bagsair bags
• pre-tensioned seat belts
• energy absorbing steering column.
Crumple zones
These are pre-deformed sections in the chassis legs and body that allow the
front and rear of a vehicle to collapse but to retain the integrity of the
passenger compartment to reduce injury to the driver and passengers.
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A chassis leg with pre-deformed sections absorbs the impact, absorbing the
transmitted energy and reducing further damage to the vehicle in minor
impacts.
Flitch panels are often drilled to help it to crumple during impact. The holes
allow the panel to ‘give’, releasing the energy created by the impact.
Side impact protection
Side impact bars in the doors and strengthened B posts and sills along with
centre cross members protect the driver and passengers when the side of the
vehicle suffers an impact.
Front and rear bumpers are made for the most part of polypropylene plastic
(which provides superior resistance) with a steel or aluminium impact bar
behind. This provides protection at low impact speed.
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SRS Airbag
SRS (Supplementary Restraint System) air bags are now commonplace.

Airbags are now positioned to protect the driver and passengers in the event
of impact from virtually any direction with the exception of rear end shunts
(where the head restraint is of primary importance). Driver’s airbags are
housed within the steering wheel pad, passenger airbags within the
dashboard, curtain shield airbags in the roof runner trim and side airbags in
the seat back.
Some manufacturers are now fitting airbags to protect the driver’s knees and
also airbags that deploy across the front screen. Rollover protection airbags
can now be found under roof linings on high specification vehicles. Airbags
are explosive devices and can cause serious injury if dealt with incorrectly.
Technicians must not work on such systems unless trained to do so.
Seat belt pre-tensioners
Seat belt pre-tensioners work in conjunction with frontal protection airbags.

Upon deployment of the front airbags, explosive charges remove any slack
from the seat belt preventing the occupant from adopting a position
dangerously close to the deploying airbag. The importance of wearing
seatbelts in a vehicle equipped with airbags cannot be over stressed. Without
this restraining mechanism, airbags can indeed be lethal. Hence the term
SRS – Supplementary Restraint System.
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Energy absorbing steering column
In heavy frontal impacts, the steering column can cause considerable injury to
a driver thrown forwards in their seat. To reduce this likelihood, steering
columns are now designed to collapse in a controlled fashion therefore
absorbing the energy of this impact.
The diagram above shows the mechanism at the heart of this system. The
inner steering column is fabricated in two parts mounted concentrically and
pinned together. These pins are designed to shear in the event of sufficient
axial force. In addition to this, the steering column outer is mounted to the
bulkhead by a bending bracket. As the name suggests, this bracket bends to
aid energy absorption.
It should be noted that this system is surprisingly vulnerable to damage during

stripping activities if the correct tools are not used. Worst-case scenario – the
pins are weakened during removal and refit and they shear during high speed
cornering. Always use the correct tools!
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Active systems
The following are examples of active safety systems:
• ABS
• VSC / ESP / DSC
• collision prevention systems.
ABS (Anti-lock Braking System)
ABS is designed to prevent wheel lock up during emergency braking. A

vehicle decelerates less efficiently with locked wheels and directional stability
is completely lost. The ability to steer around obstructions during emergency
braking can help prevent collision.
VSC (Vehicle Stability Control)
Vehicle stability control is a system that reduces the tendency of a vehicle to

understeer or oversteer during high speed cornering. This can help prevent a
potentially dangerous vehicle attitude that the driver finds difficult to recover
from. Manufacturers use different terms for this system and the following are
typical:
• ESP - Electronic Stability Programme
• DSC – Dynamic Stability Control.
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Progress check 5
1. Name two types of active safety systems:
2. Name two types of passive safety systems:
3 What does a seat belt pre-tensioner do?
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Body Deformation and the Ripple Effect
It is advantageous for a vehicle’s chassis to deform during impact as this

process absorbs the energy of the impact. Major injury results from a high
rate of speed change during the impact. If this process can be slowed,
survival chances will increase. Deformation of the chassis slows this rate
considerably.
The drawback of this process (albeit a minor one when considered in context)
is that a relatively minor impact can create considerable damage through what
is known as the ripple effect. A minor frontal collision can result in damage
being sustained towards the rear of the vehicle also. This can make repairs
very costly.
Secondary damage can also add to repair costs. The picture above shows a
potential source of such damage.
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Benefits of safety systems
The design and production of crumple zones or passive and active safety
measures over the last few years have meant that even after heavy impacts
car drivers and passengers are receiving less serious injuries due to vehicle
accidents. In the case of strong impacts from the front, air bags deploy rapidly
in order to reduce the possibility of the head and upper torso colliding directly
with the steering wheel or instrument panel. Seat belt restraining time is
quicker to improve initial restraining performance and the force limiter in the
seat belt absorbs the energy and reduces the load on the torso.
The crumple zones absorb the impact front and rear on the vehicle body,
minimizing injury to occupants from the engine compartment or boot area.
Safety glass lessens the chance of serious cuts and facial injury from the
windscreen and side glass. Side impact bars and side air bags protect
occupants from serious injury when involved in impacts from the off side or
near side of the vehicle. All of these safety measures have led to fewer
fatalities and less serious injuries due to car collisions.
Regulations
The EU and the Department for Transport (DfT) govern regulations on design
and construction of motor vehicles. These departments ensure that motor
manufacturers comply with all safety legislation and that vehicles are crash
tested and components tested to their limits. Approved centres such as Motor
Insurance Repair and Research Association (MIRRC) at Thatcham are
supported and approved by the Government and the motor industry to ensure
that all vehicles comply with the regulations relating to the construction,
design and safety of motor vehicles.
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Progress check 6
1. Name one application of aluminium in a vehicles construction:
2. Is Kevlar natural or synthetic?
3. Where is a flitch plate located on a vehicle?
4. What is ‘Ripple Effect?’
5. What is ‘Crumple Zone’?
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kap all covers 6/9/03 9:48 am Page 7

Seat belt pre-tensioners 38

Body Deformation and the Ripple

Metals form the major make up of a vehicle’s construction. The properties

• ductility – can be drawn into wire

• malleability – can be rolled and hammered into sheets and foil

• large specific gravity (dense)

• high in electrical and thermal conductivity.

High strength steel plate

Tin is used to a limited degree in vehicle construction, as it is prone to

Non-metallic materials are used in abundance on modern motor vehicles.

A selection of plastics that are regularly used in the construction of motor

Plastics are classified as either thermoplastics or thermosetting plastics. A

Rubber can be either natural or synthetic (man made). Natural rubber is

Synthetic rubber is an elastic polymer and tends to be far more suited to

Totally tempered glass

Totally tempered glass is heat-treated in accordance with the diagram above.

To laminate means to layer. Laminated glass is two thin sheets of glass

Kevlar is a manmade organic fibre introduced in the early 1970’s. It combines

• bullet proof vests

• Formula 1 racing car bodies

• brake pads and clutch linings

• data transmission cables

• vehicle body panels.

2. In the context of plastics, what does ABS stand for?

3. What does synthetic mean?

4. List five applications for Kelvar on a motor vehicle

Doors, bonnet and boot lid

It is important to understand that all component parts that go up to make a

A wing can also be a fender; a doorsill a rocker cover, a bonnet could be

A ‘cant rail’ is a name given to a strengthening structure running from front to

A ‘flitch plate’ is a strengthening plate inside a beam.

Spoilers and air dams

A sub-frame is often used to mount the major assemblies on a vehicle

The roof panel is a major structural member, experiencing considerable

• boot floor side extension.

Many different methods are employed to fix panels to a vehicles chassis.

• speed clip and speed bolt

Screw Hex screw

A typical specification could be:

• 75mm long, M8 coarse thread, strength rating 8.

Castellated nut Wing nut Shear nut

MIG Welder Spot Welder

Door lock mechanisms differ greatly in design between manufacturers, but a

Many different cross-sectional shapes are available to realise good sealing

1. What do other countries sometimes call a bonnet?

2. What is the fixing device pictured called?

3. What is the purpose of a spoiler?

4. If a vehicle is leaking water from around the windscreen what is the

Label the following body styles with the correct name:

Many different types of chassis construction methods have developed over

Self supporting frame

A composite designed vehicle is a chassis with a fibreglass or carbon fibre

A skeletal structure formed from sections of steel pipe. It is very costly to

1. What is the difference between a self-supporting frame and a

2. Name one advantage of carbon composite chassis construction:

3. Why do certain structural members have to be strengthened on a

4. What is the most common type of chassis used on commercial

5. List two advantages of monocque construction:

Constructed of steel pipe welded together to form a skeleton. As the chassis

1. Name one load bearing point on a monocoque chassis:

2. What type of vehicle often uses a ladder frame chassis construction?

3. How is a ‘list rail’ positioned on a chassis?