Time flies. In the collision repair industry, it seems to move especially fast. It seems like just yesterday that shops were first dealing with issues like how to repair high-strength steel (HSS) and ultra-high-strength steel (UHSS) structural parts. OEM information was tough to come by, and repairers struggled with problems such as sectioning these parts or doing full replacements, which was followed by the inevitable debate with insurers over the best choice. Just as these issues were being worked out, the influx of sensors throughout vehicle bodies shined a new light on the necessity to ensure every structural repair was performed accurately the first time to keep safety systems working properly. These days, the challenge continues as shops must keep up with the steady river of new repair information and the need to replace old equipment with new.
Fortunately, you’re not alone on your structural journey. I-CAR, vendors, your fellow repairers, and others are there to help. With them, here are seven structural repair tips from experts designed to keep you on track.
Tip 1. You’re probably on the right track, so stay there!
Keeping up with constantly evolving technology is a chore, but overall, the repair industry is on the right track. “Shops are getting better with staying informed and performing proper repairs,” says Robert Hornedo, president of Pacific Collision Equipment Company in Signal Hill, California, at the time of this interview. (Editor's note: It was announced Nov. 21 that Hornedo had sold Pacific Collision Equipment Nov. 5 to Kalix River Holdings.)
Hornedo says that one of the biggest changes he’s seen in the automotive industry over the past three decades is the precision in the manufacturing process, which requires repairers to be much more aware of the consequences of an inadequate or insufficient repair. Vehicles now have between one and one and a half millimeter tolerances, so there’s a very slim margin for error. Hornedo notes, “I'm really happy to see so many shops being aware and more conscientious of the quality of the repair. They know what the consequences could be, and I think as shops continue to pursue OEM certification, more will reach the same realization.”
Still, there’s also plenty of work to be done since he also notes that within a radius of just a few miles of his business, he’s familiar with 20 shops struggling with being fully professional businesses. But they’re trying. That attitude is significant, since Hornedo says it demonstrates that many shops recognize there’s an opportunity to make money and be successful if they continue to invest in quality work.
Tip 2. Accurate structural repairs start with professional damage analysis.
A truly thorough (professional) analysis involves measuring with a 3D measuring system. Structural damage, even if it’s significant, may not be detected simply by sight or may appear to be light to moderate. Buckles and bends might not appear.
Hornedo and Bret Runyon, territory manager for Spanesi Americas, explain that HSS and UHSS structural components are designed to absorb or transfer energy. Shops must then examine these energy transfer points, which are located throughout the whole frame rail. Moreover, components of that frame rail, especially hydroformed steel, may feature multiplelayers of different kinds of steel. “After a collision, if you didn't measure the vehicle, you’d never noticed that the rail is three, four millimeters back since, structurally, the whole thing moves,” Hornedo says. “You might end up buying a new hood, a new bumper, a grille, and fender, and after installing them, discover things still don’t line up.” Then you’re stuck writing up supplements, gaining insurer approvals, and trying to explain to frustrated customers why they’re getting their vehicles back later than expected.
Without measuring during damage analysis, you’ve opened the door to creating a mess. Finding your mistakes then, or by waiting until measuring until after the work is complete is a recipe for costly mistakes. Put your 3D measuring equipment to work before the estimate is written.
Tip 3: Rid your shop of older, problematic equipment
While you need to consistently use your measuring tools, your shop would be well served if you removed (or sidelined) older equipment that can cause you problems. For structural repairs, you should know by now that pinch weld clamps no longer have a place. Runyon recommends mothballing any tie-down chain and binder, along with no longer using full-frame clamps.
Hornedo says shops need to abandon frame machines. “By that, I mean those frame machines that are not machine-milled benches, because there's a definition between the two,” he explains. “Those are totally inaccurate and crooked and even from the factory when they’re brand new, they're crooked. When you have a vehicle that's manufactured with two-millimeter tolerances or less and you put it on top of a crooked frame machine, you end up with a crooked vehicle.”
Couple that with an inadequate measuring system that just averages numbers (more equipment you need to remove), and you’ll be sending out a steady stream of structurally compromised vehicles.
Tip 4: Understand what goes on in the factory.
Knowing how to repair something often begins with understanding how it was originally assembled. This is particularly true with structural automotive repairs. Consider that modern automobiles are largely assembled by robots that perform precise, exacting work. Your repairs need to be performed with the same dedication to precision. This isn’t simply true for luxury or high-end models. Hornedo notes that even the least expensive vehicles. “The integrity of the build of all the vehicles is without question, so the integrity of the repair must be the same.
Tip 5: Invest the time necessary to find the correct repair procedures.
Long gone are the days when shops struggled for access to OEM repairs and information. Repairers can still face challenges locating procedures for up to date, thorough structural work. Runyon says there is so much information available, shops need to find ways to navigate through it. Further, the folks doing the navigation aren’t always “body guys.” Faced with these challenges and believing they have time to dig through new information, shops will return to handling repairs they always have, he adds. In addition, negotiating with insurers to pay for research time can be defeating. If that weren’t enough, Runyon says shops sometimes find the need to juggle OEM repair subscriptions. He says some will get a three-day subscription to ensure insurers reimburse them while forgoing an annual subscription that might not be.
Though these challenges can prevent shops from accessing the critical procedure they need, both Runyon and Hornedo say these difficulties must be overcome. The consequences are too serious to ignore. Shops, therefore, would do well to set up a process to access this information, whether that means putting a staff member in charge of this work, keeping techs well trained in structural repairs, and/or ensuring estimators are trained as well.
Tip 6: Don’t hesitate to ask for help.
With all the challenges you face in the collision repair industry, remember that you’re never alone. If you’re looking for help to either keep or put your structural repairs on the right path, assistance is readily available. Runyon says shops can turn to their local state associations, many of whom are holding structural repair educational days, and the Society of Collision Repair Specialists. Companies like Spanesi and Car-O-Liner also have plenty to offer, including product support for their structural equipment and training in areas such as 3D measuring and damage analysis.
Just as important, they can offer guidance on how to best assemble and finance your structural repair equipment. “To do this work, you need a smart spot welder, a repeatable, reliable electronic measuring system, and an OEM-certified bench. Those are things you have to have, but if you can't afford to do them all in one shot, what do you do?” Hornedo says. “We can give you help like suggesting you prioritize. Ask yourself, ‘What comes first? What's going to help me in my business the fastest, the quickest, best return on investment so that I can go to the next step?’”
Tip 7: Stay focused on the customer.
If you still need a “glue” to bind you – and every part of the industry - to keeping up with evolving structural work, look no further than doing what’s best for vehicle owners. “Stay focused on the customer, and everybody will win - insurance companies included,” Hornedo says. “The more educated the shops are, the faster they're able to repair cars, which will reduce labor, rental, and other costs.”
He and Runyon agree that education of shops, their estimators and techs, and insurance companies is the key. “We all want the same thing,” says Hornedo. “We want to make a living, and that always starts with doing the right thing for customers. We all have to give customers what they deserve, and we do that by agreeing and understanding what the best repair is and sticking by that.”
