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Tag Archives: auto body repair

Variety of orbital sanding machines. Difference not to be ignored.

When we speak about different aspects of the car body repairs, usually we mainly discuss the quality of the materials, especially chemicals. No doubt, the final result of any refinishing job depends on paint, clear or primer used. However, it is of utmost importance not to forget how important is the preparation stage, including such a tedious task as sanding.

Just after the Christmas holidays, during the paint preparation workshop in the company’s training center, I came across an interesting question from our customer. This quite an experienced painter was testing different brands of abrasives together with our technical specialist. While I was discussing something with one of our sales manager, I overheard a heated discussion between the painter and our technician. The argument was about using P400 abrasive disc with 5mm orbit sander. “I only use 5mm orbit, and there is no need for any other model”, the painter said with confidence in his voice. “All these different orbit sizes are just made to make us buying more unnecessary tools”, he added. If you ever had an argument with a painter, you probably know that they are hard to convince about pretty much anything. “Show me the difference “, exclaimed the painter. Therefore, we decided to give it a try.

The rule of thumb

Probably you know the recommendations of tools manufacturers. For the abrasives with grits from P80 to P180 use a sander with larger orbit of 5-6mm, while for the finer sanding jobs with P240-P600 – orbit of 2.5-3mm. Some of the manufacturers also offer machines with rather big orbit of up to 10mm for demanding paint stripping operations; however this kind of sanding tools are not common. What is usually missed in those recommendations, it is the explanations behind this information.

In reality the theory behind is very simple. A large orbit allows the abrasive to cover bigger surface and to remove the “picks” of the uneven surface faster and more effectively. On contrary, smaller orbit covers smaller area, but more densely, leaving smoother surface.

From our internal tests, we found that 5mm orbital sander with the same abrasive and all other conditions the same, removes up to 20% more material than 2,5 mm orbit. This is very important especially in paint stripping or body filler sanding jobs. On the other hand, finer grits load up less when used with smaller orbits, like 2,5-3 mm. This allows achieving better quality surface at less time.

Take away

The choice of tools and materials is a painter’s undisputed prerogative, however we all should not ignore the common sense and facts. Doubt is good only when it pushes one to explore and search for facts. If facts are obvious, ignorance in this case is unacceptable. Using recommended sanders will save you time and money. Proved!

Do not start a new bodyshop without thorough consideration of these aspects.

Recently I have been involved in the planning session for a brand new bodyshop for servicing municipal bus fleet of one of the capital cities in Europe. While this process is not something new or unique to me, I had an opportunity to get into customer’s thinking and logic. And, I assure you that there is no better way to understand your customer, than to be in his shoes for a while. During the numerous round table meetings, I realized that there are certain key aspects one must consider while planning a new shop. Failing to make the right decisions on those aspects will make the future of the workshop seriously difficult. Below I will analyze how to make vitally important decisions on a bodyshop space and layout, key equipment and paint supply. Additionally you will find some useful links curated especially for you on this subject.

Space and bodyshop layout

Working space is probably the most expensive and vastly important asset of any business, and collision repair businesses are not an exemption. Here we need to distinguish two possibilities. First possibility is when you are already given a certain building to fit your new shop in. Second possibility allows you to build the new shop from scratch. In the first case, a deep analysis of the given space must be considered. For example, in the project I referred above, the initially proposed building was quickly dismissed, because number of restraints for a spray booth and prep area location. Second possibility is only limited by the budget, and it is a much easier option for any organization.

Advice 1

Never underestimate the importance of space in a bodyshop planning. For example in Greece, more than 50% of the bodyshops lack the vital space for easy moving the vehicles around the shop. As a result, body and paint shops become bottlenecks, causing delays in vehicles deliveries, while decreasing overall profitability. Remember that it is much easier and cheaper to lay out the shop correctly form the beginning rather than make adjustments later on. Additionally, allocate space for spare parts storage, paint mixing room, dressing rooms and a place for employees break.

Additional reading link:

http://etalon.gr/blog/2013/08/08/4-ways-to-speed-up-your-body-shop-productivity-1/

Equipment

Every new bodyshop requires a great number of equipment and tools for its operations. I don’t want to talk about everything, but three main ones: a spraybooth, a bench and a compressor.

Spraybooth

Probably when you imagine a car painting shop, the first image coming to your mind would be a spraybooth. It is probably the most expensive piece of equipment in the paint shop, so, needless to say, it is of a paramount importance to avoid any mistakes here.

Advice 2

Nowadays one can find a great deal of spraybooths for any budget and special requests. From many years of experience, I can assure you that the most important factor for choosing one booth over another should be a supplier, not the technical characteristics. Invest your money having in mind the proximity of the supplier, his experience, technical stuff and spare parts availability. Trust me, you don’t want a supplier of a spraybooth, who can not fix any problem within 24 hours. Ask your colleagues who have different brands of spraybooths installed. Are they happy with it? Are they satisfied with the after sales service?

Additional reading links:

https://www.dtc-uk.com/spray-booths/choosing-the-right-spray-booth/

https://www.pfonline.com/articles/7-steps-to-make-buying-a-paint-booth-easier

https://www.autobodytoolmart.com/paint-booth-size-guide-t.aspx

Bench

If your workshop will perform also the complicated panel beating works then you must decide on the purchase of a bench. Straightening benches are also expensive and require good market research.

Advice 3

Make sure that you understand the insurance companies’ policies on severely damaged vehicles. In many countries, insurers prefer to scrap a vehicle with serious structural damage rather than fix it. Once you know what will be the majority of insurance jobs, you will be able to choose the right equipment without overpaying for the unnecessary options.

Additional reading link:

https://www.bodyshopbusiness.com/frame-rack-or-bench-which-is-right-for-your-shop/

Compressor

It is difficult to overestimate the importance of the air supply in any bodyshop. Spray guns and airtools are all essential to the efficiency in any collision repair shop. Before deciding what capacity of the air supply your shop should have, you must study carefully the technical characteristics of the spray guns and pneumatic tools to be used. Place, where the compressor will be, piston or rotary technology, length of the air supply network and potential air losses – all these crucial parameters must be carefully calculated.

Advice 4

Allocate adequate funds for the compressor to cater for all the needs and exceeding the estimated air supply capacity for this workshop at least by 15-20%. Compressor is not a piece of equipment to save money on. Consider a secondary backup compressor in case of the breakdown of the primary compressor. Choose a supplier who has the experience with paint shop needs. Keep in mind that air purity, absence of water and oil in the air system are important in the bodyshops like in no other workshop.

Additional reading links:

https://www.bodyshopbusiness.com/buying-tips-air-compressors/

https://www.bodyshopbusiness.com/air-compressors-what-to-consider-when-buying/

https://www.thecompressedairblog.com/compressed-air-application-automotive-paint-body-shop

Paint and consumables supply

Likewise, choosing the paint and consumables supplier is not an easy task. Probably the two most common mistakes I see in the market are choosing a potential supplier based on price or on “freebies”. Both decisions patterns may seriously affect negatively the future of the business.

Advice 5

Do not choose your paint supplier based on the price alone. First, the price and the cost are not the same things. Cheap may be very costly when it comes to the productivity. Initial “sweetness” of low price will fade out quickly when quality issues appear or/and due to the bad service a “cheap” supplier provides.

Another common trap is when a potential paint supplier offers expensive “gifts” in order to get your business. “Free” spray guns, tools or even a spraybooth, are actually always included in the future bills. The cost of those “freebies” is disguised, but you will always pay them back with a high interest rate. No suppliers, especially multinational paint companies, are charitable organizations.

Additional reading link:

http://etalon.gr/blog/2017/08/27/buying-bodyshops-business-paint-companies-sustainable/

Sum up

If you are in the process of the new bodyshop set up, please do not rush your decisions. A great number of businesses are doomed to failure before even opening their doors. You might be tempted to speed up the whole process to start working as soon as possible. However, a few weeks delay, spent on the meticulous preparations and research, will save you tones of money and put the solid bases for the future success.

 

Color matching problems not related to the paint itself

Probably color-matching problems are among the most frequent paint defects in the car refinishing industry. It is also the main cause of expensive re-works and unhappy customers. In many cases, the poor color-matching is due to the darker or lighter appearance of the final result. Below I bring to your attention 6 parameters a painter should consider before the basecoat application:

Spray gun pressure

Unfortunately, many painters underestimate the importance of precise measurement of the spray gun inlet pressure. They either do not use a manometer at all, or rely on a poor quality analog manometer.

Outcome: Lower than designated pressure causes darker color result, while higher pressure – lighter color than needed.

Solution: Use a reliable manometer, preferably digital one, for each basecoat application job.

Humidity

Most of the paint manufacturers state the ideal humidity level for the perfect applications conditions. However, we do not have the possibility to control humidity levels easily. For your reference, ideal humidity level is between 30% and 50%, lower than 30% humidity is considered low, while higher than 50% humidity is considered high.

Outcome: Low humidity causes darker result, while high humidity – lighter result

Solution: Adjust viscosity based on the instructions from paint manufacturer, consider changing nozzle size and air cap with lower or higher air flow (consider switching between higher air volume HVLP technology gun and lower volume Devilbiss Trans-Tech or High Efficiency or SATA RP).

Temperature

Just like with humidity, every manufacturer advises the optimal temperature levels for the application. Unlike humidity, it is easier to adjust temperature levels in a workshop, but still there are limitations as well. As a rule of thumb, low temperatures can be considered the range from 15 to 20° C, normal – 20-25° C and high – 28-35° C

Outcome: Lower temperatures will cause darker results, while higher temperatures – lighter results.

Solution: Adjust viscosity based on the instructions from paint manufacturer, consider changing nozzle size and air cap with lower or higher air flow (consider switching between higher air volume HVLP technology gun and lower volume Devilbiss Trans-Tech or High Efficiency or SATA RP).

Thinning (dilution)

Every single automotive coating product comes with a detailed technical data sheet. Unfortunately, often painters either ignore those data sheets or simply continue to work with any new product the “good old way”. In reality, under thinning or over thinning will inevitably cause color problems.

Outcome: Under thinning will cause darker color shade, while over thinning will produce lighter than needed variation.

Solution: Follow the manufacturers’ technical instructions, labels and manuals. Use mixing cups with measurement marking, scales and mixing rulers.

Spray gun distance from the surface

Every sprayer has its own style and spraying technique, however certain standards must be respected. One of the parameters I refer to is a distance between the spay gun and the vehicle’s surface. Consider that normal distance lies within 15 to 25cm range.

Outcome: Too small distance will cause darker colors, too high distance – lighter variation.

Solution: Respect the advised distance between the gun and the surface.

Speed of spraying

Similarly, speed of paint application is very individual and varies from sprayer to sprayer. However, extremes are not good.

Outcome: Spraying with too low speed will cause darker colors, while spraying at excessive speed – lighter color than expected.

Solution: Follow the paint and spray gun manufacturers’ instructions.

 

Spray gun vs iPhone. What a dilemma.

This blog post is not about the new technology in automotive repair industry, nor about its challenges or best practices. This post is about a crisis we definitely have in our industry. This is the human resource crisis. No matter how precise the color matching is, or how fast clearcoats dry, if we don’t have skilled, motivated and proud painters, the industry’s future is not bright. In fact, this post blog comes as a continuation of one of my recent articles “The biggest challenge in the collision repair is to keep it young.”

Just last week we had a round of presentations of new Devilbiss spray gun DV1 on the field. Usually I enjoy this part of my job. What can be better than a direct, unfiltered contact with the end users of your products? While the presentations were “business as usual” , one encounter left me very concerned and in doubt.

My sales manager and I visited a very typical for Greece bodyshop. Average size, family owned workshop of three people. The painter was actually the owner’s son, and the next generation of the business. After initial formalities and casual chat, I asked the young guy about his spaying equipment arsenal. It turned out that he is using two spray guns for basecoat and clearcoat applications. One was a Devilbiss GTI – the very first model of the iconic blue spray gun by the British manufacturer. The other piece was a SATA 2000 model. Both spray guns were purchased many years ago by the painter’s father, and they have obviously seen better days. Looks like a good potential customer, you may think. I thought the same exact thing. However, the youngster looked very indifferent and reluctantly asked for the price. The average retail price for a premium spray gun, regardless of the brand is slightly above 700 Euro in our part of the world. If you take in account that with a quality piece of equipment like Devilbiss DV1 or SATA Jet 5500 (I don’t mention other brands, but the list is not all-comprehensive) one could save massively on materials consumption, improve color matching on difficult metallic colors and decrease re-works, purchasing such gun is a no-brainer. Well, for me at least. However, my prospect customer had a different opinion.

“That is too expensive”, he replied indifferently and took a brand new iPhone XS Max out of his pocket. He started clicking through some Viber messages and turned his back to us. Our pitch came to an end.

En route back to my office I was thinking a great deal about this young man. I wasn’t thinking about the rejection. No. If you are in sales, you know that rejection is just a part of everyday life. What stroke me most is that the “professional” painter didn’t show any interest for something new in his industry. It wasn’t the question of money, of course. Someone who can afford buying an expensive gadget worth about 1300 Euro, can afford investing in his job. Unlike pricy phone, the last technology spray gun (or any other piece of equipment) will earn him money. The problem is that investment in his work is not something he wishes to do, and it is important to distinguish between investment and pure expenses. Purchasing a piece of equipment is definitely an investment. Buying a new phone, unless you are mobile app developer, is an expanse.

To conclude, I would like to say that there are people in our industry who struggle to make both ends meet. Probably not everyone, especially in crisis-hit Greece, can buy a DV1 or similar spray gun. However, a serious sprayer would rather save money for a gun, rather than for a phone. This is my humble opinion.Chances are that this bodyshop will not survive until the next generation, unless the owner changes his attitude.

 

Global Color Popularity Infographics 2018

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