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Materials used in manufacturing automobiles are changing rapidly. BMW and Jaguar, in particular, now use aluminum components in their higher-end models. Aluminum requires different repair techniques and special machinery, requiring shop owners to make decisions on whether or not to purchase equipment dedicated to aluminum repairs that may or may not transpire.
| | 2004 BMW 6 Series mounted on a Car-O-Liner Mark 6 Repair System. |
The dedicated bench that most repairers of high-end vehicles have been using is an expensive investment, with modifications needed for each vehicle model. Fixtures must be purchased or leased at a hefty cost for each separate repair. A simple accessory from Car-O-Liner - Car-O-Flex - can be added to new or existing Car-O-Liner benches enabling them to fixture cars into place precisely to manufacturer's specifications It is a one-time expenditure and any vehicle, aluminum or not, can be repaired with the system which handles 10,000 different models of vehicles. Car-O-Liner is approved for repairs by BMW and, more recently, Jaguar. Approved by BMW The Car-O-Liner/Car-O-Flex system has been approved by BMW since 1998. The product has been around since 1995, giving some shops a head start on aluminum repairs. With the release of the BMW 5 and 6 series, new challenges arose. The vehicle has to be fixtured and held in place in order to make proper repairs. The aluminum front structure is bonded and riveted to the steel body. Director of Technical Service and Training for North America for Car-O-Liner Tim Morgan further explained that specific repair methods have to be followed. "Special equipment must be dedicated to aluminum repairs. Car-O-Flex is a universal fixturing system that works on all vehicles. "To set the parts in place and hold them during the bonding and riveting process, the vehicle has to sit in the fixtures for 12 hours to air cure, during which time it must be held rigid.
 | | The 5 Series BMW with both upper support carriers removed for replacement. |
A way to expedite the curing process is to put the vehicle on the frame machine into a spray booth at 150 degrees F metal temperature where it will set within an hour. The Car-O-Liner Mark 6 mobile bench, in conjunction with Car-O-Flex, is a perfect fit for that procedure. Unique repair process The repair process is unique because no straightening or heating is permitted on the aluminum parts. Conditions can occur where glued seams could come loose or fatigue of rivets occurs. Any reshaping of the part could cause up to 40% loss in structure. The strength of the repair is a combination of the riveting and bonding over 80% of the structure. Repairing aluminum requires specialty welding tools and adhesive applicators, which must be approved by the vehicle manufacturer. The only glue material allowed by BMW is a Dow Chemical product called BetaMate 2096. Car-O-Liner also offers resistance spot welders which are UL and ETL-approved, and approved by OEMs including BMW, Toyota, Lexus, and Volvo. No contamination! Another major concern is that aluminum vehicles cannot be repaired in the same area where steel vehicles are being worked on. If steel particles land on the vehicle, they can cause galvanic erosion to the aluminum. The repair area must be in a curtained area with an extraction system or in a separate building altogether. In addition, a complete set of tools must be dedicated to aluminum repairs to avoid cross contamination with steel. 
| | Vehicle front section at Car-O-Liner Company Training Center used to demonstrate Car-O-Tronic Vision and Car-O-Flex Fixturing. |
 Robert Hornedo, Pacific Collision Equipment Company, Signal Hill, California, commented that "the dilemma with aluminum repair is that it must be absolutely perfect. BMW approved the Car-O-Flex product because of its precision for their vehicles. There are many BMW dealership collision repair shops that are now using our system." Dedicated benches "For the average body shop, it is not cost effective to invest in a dedicated bench with specific fixtures for each type of vehicle," said Hornedo. "It would be impossible to keep up with car models that are changing faster than ever before as manufacturers try to keep consumers turning over their vehicles for the latest and greatest the manufacturer has to offer."
 | | Technician removes panel with cut-off saw in designated sectioning area. |
Body shops with dedicated benches may try to pass the cost of the fixture rentals on to the insurance companies, who may be reluctant to pay these costs now that there is an alternative. In addition, using the dedicated fixture-type bench may require R&I of the suspension which is a further expense to the insurance company, particularly since mechanical repairs are paid at a higher labor rate than collision repairs. "Car-O-Liner machines are manufactured to such a tight tolerance, they are built even better than the cars," explained Hornedo. "Without that platform being perfect, you are not building a straight car. Hand-made machines are crooked and have a build tolerance that exceeds the build tolerance of the car. With Car-O-Liner, you have a perfect foundation. That's why the quality of the repair is so high." Training on new machines Training is very important at Pacific Collision, a complete provider of all Car-O-Liner products. The company wants their customers to use the equipment to its maximum efficiency, so training classes are offered in both English and Spanish for one year from the date of purchase at no charge. Wireless measuring system Another product that can further enhance the repair process is the Car-O-Tronic Vision measuring system, which is 100% wireless with no targets or sensors to add to the car. This system has complete upper body measuring capability. "After all, if you can't get the roof on straight, the rest of the car won't line up," pointed out Hornedo. In conclusion, Hornedo describes Car-O-Liner as a "silent giant that designs and builds the best equipment in the world." For more information, visit www.crashtools.com to see the full Car-O-Liner product line. |
