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Toby Chess

Toby Chess is an I-CAR program instructor, training specialist, and former salvage yard operator. Toby is universally known in the collision industry for his work with first responders and advocacy for body shops and consumers. He can be reached at tcspeedster@gmail.com.

Wednesday, 13 August 2008 17:00

HEY TOBY 6: Squeeze-Type Resistance Spot Welding

Written by Toby Chess

Hey Toby—Thank you for the resistance spot welding class you conducted at our Chatsworth location the other night. The class was very helpful in several ways:

The in-class technical information portion was helpful in understanding the increasing usage by auto manufacturers of advanced high strength steels and the importance of proper welding techniques needed to retain metal strength.    

The actual hands-on portion of the class was powerful in that we could utilize the latest state-of-the-art equipment you provided for the class and actually test the strength of the welds we performed.  
Overall, the class was beneficial for a better understanding of the importance of proper squeeze type resistance spot welding related to advanced high strength steels. Thank you for conducting the class!
—Frank Schiro

Hey Toby—I want to thank you and I-CAR for the Squeeze-Type Resistance welding class you put on for Holmes Body Shop in Canoga Park last night. My repair teams gained valuable knowledge and experience in spot welding. Not only that, but it was enjoyable for all of us to learn on some the newest equipment out there, in a stress free and fun environment (the class was done at Holmes Body Shop in Canoga Park).
    I heard several members of our team say “this is pretty cool”. Again, thanks to you, Prospot and Car-O-Liner.
—Steve Morris, General Manager, Holmes Body Shop-Canoga Park.

Says Toby—These are e-mails that I received the other day. Both gentlemen are referring to the Squeeze-Type Resistance Welding I-CAR Class or WCS 04.
    I started the I-CAR mobile welding Qualification test a little over three years ago and over 2100 techs have completed the test with me. I came to realize that our industry wanted hands on training conducted in the shop. I recently put on a WCS 04 class, but being in a class room, the class lacked something. That something was taking what we learned in the class and put it to use in the shop.
    I contacted Robert Hornedo from Car-O-Liner and Ron Olsson from Prospot about bring their welders to my I-CAR Class, which they both said yes. Thus was born my first in house WCS 04 with hands on training. I have conducted 4 classes to date and the reviews has been excellent. After attending the class, which is a very good orientation, the students go into the shop and Gus from Car-O-Liner and Frank from Prospot take the techs through the setup of each of the machines.
    I have made a number of different metal samples (various thickness, uncoated steel, zinc coated steel, and high strength steel) and put them into a box. The students select two samples and measure the thickness of the samples with  calipers. Both machines use the thinnest metal for setting the metal thickness on the machine. Nearly everyone in the class so far has never used a set of calipers. It is fun watching these guys learning something new.
    After clamping the samples together, each tech had to set the machine to the type of metal and the thickness. Following the set up, the techs spot welded the coupons together. The next step in the process was to perform a destructive test. Everyone had to perform both a peel test and a twist test. The final part of the practice session was to check on diameter of the weld nugget (we were looking for a 5mm diameter nugget). I also demonstrated using shunt pliers with coupons coated with cooper weld-thru primer. Everyone was able to see how STRSW does not have a large heat affect zone and it does not burn off the weld-thru primer.
    I want everyone to know that there is no additional cost for the hands on experience. The class is one I-CAR coupon and Kent Automotive has supplied all of the metal and the products for the class. Prospot and Car-O-Liner have loaned me both machines so that I can continue to bring to bring the industry this inhouse training.
    You can reach me at 310-995-7909 to set up this class or the steel and aluminum qualification tests.

P.S.—I am working an aluminum repair class for the shop—I will let everyone know when it is ready.

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