COMPETENCY BASED-LEARNING MATERIAL
Sector:
Automotive Sector
Qualification:
Automotive Body Repair and Paint Work NC II
Unit of Competency:
Perform Automotive Body Repair and Paint Work
Module Title:
Carry-out Basic Panel Repairs
VMC ASIAN COLLEGE FOUNDATION, INC.
28 National Highway, Tacurong, City, Sultan Kudarat
Automotive
Date Developed: April
9 2025
Page
Checked by:
Body Repair and
Paint Work NC II
Developed by:
Esclamada, Marven G.
Christyl Mae R. Vidal
TABLE OF CONTENTS
Contents:
Introduction to the Module…………………………
List of Competency………………………………………
Session plan………………………………………………..
Module Content………………………………………….
Data Gathering Instrument…………………………
Information Sheets 1…………………………………..
Information Sheets 2………………………………….
Self Check 1……………………………………………….
Self Check 2……………………………………………….
Job Sheet 1………………………………………………..
Job Sheet 2………………………………………………..
Answer Key……………………………………………….
Performance Criteria Checklist………………….
Automotive
Date Developed: April
9 2025
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Body Repair and
Paint Work NC II
Developed by:
Esclamada, Marven G.
Christyl Mae R. Vidal
Introduction to the module
In automotive bodywork measurement and quantity estimation of bodywork project
helps to know the quantity of work; estimate the required amount of material; determine
the cost of the work; estimate the expected project completion time and to know the
amount of material supplied for bodywork This module describes the performance
outcomes required to carry out essential repairs to vehicle body panels. It involves
planning and preparing for the task, identifying and using abrasives, body fillers, and
heat shrink and metal finishing procedures, selecting and using tools and equipment,
and maintaining the work area, tools and equipment.
Automotive
Date Developed: April
9 2025
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Body Repair and
Paint Work NC II
Developed by:
Esclamada, Marven G.
Christyl Mae R. Vidal
MODULE CONTENT
Perform Automotive Body Repair and Paint Work
Unit of Competency: Perform Automotive Body Repair and Paint Work
Module Title: Carry-Out Basic Panel Repairs
Module Description: This module covers the skills, Knowledge, and attitudes required
to perform basic repairs on vehicle panels. It includes dent removal, use of body filler,
sanding, and surface preparation using basic tools and techniques, ensuring restored
panels are ready for refinishing.
Nominal Duration:
200 hours
Qualification level:
NC II
This module covers the following units:
 Prepare to Repair Body Panel
 Carry Out Basic Panel Repairs
 Complete Work Processes
Learning Objective of the Module
 Prepare to Repair Body Panel
 Perform Carry Out Basic Panel Repairs
 Complete Work Processes
Resources:



Laptop
WiFi/Data
Learning Materials
Automotive
Date Developed: April
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Paint Work NC II
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Christyl Mae R. Vidal
DATA GATHERING INSTRUMENT
Title: Trainees Performance Survey
Module: Carry out Basic Panel Repairs
Assessor/Trainer: Esclamada, Marven G.
Date:
PERFORMANCE EVALUATION
Evaluate trainees based on their performance
1-Not Yet Competent
2-Needs improvement
3-Competent
4-Highly Competent
Learning
Outcomes
LO1.
Identify
damage
Performance Criteria
1
2
3
4
Remarks
Identifies panel damage
accurately
LO2
Recommends proper repair
method
Select correct tools for the task
Use tools
LO3
Uses tools correctly and safety
Prepares work area and panel
Dent
removal
LO4
Removes dents with proper
technique
Applies and shapes filler
properly
Apply filler
LO5
Sanding is smooth and
consistent
Sanding
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Date Developed: April
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Christyl Mae R. Vidal
PERFORMANCE CRITERIA CHECKLIST
Module Title: Carry out Basic Panel Repairs
Trainer/Assessor: Esclamada, Marven G.
Name of Trainee:
Performance Criteria
Competent
Not Yet
Comments
Competent
1. Identifies panel damage and select repair method
1.1. Accurately identifies the type of panel damage
1.2 Assesses damage for repairability
1.3 Chooses appropriate repair tools and methods
2. Observe workplace safety and use PPE properly
2.1 Wears appropriate personal protective equipment
(PPE)
2.2 Follows safety protocols and procedures
3. Uses panel repair tools and equipment correctly
3.1 Select the correct tools for the task
3.2 Handles tools safely and efficiently
3.3 Maintains and stores tools properly after use
4. Performs dent removal using basic techniques
4.1 Prepares and secures work area
4.2 Uses hammer, dolly or suction puller effectively
4.3 Removes dents without causing further damage
5. Applies and shapes body filler
5.1 Mixes filler with the correct ratio
5.2Applies filler evenly over the damaged area
6. Sands and finishes repaired area for painting
6.1 Select the correct sandpaper and sanding tools
6.2 Sands filler smoothly and evenly
6.3 Cleans and inspects panel for paint preparation
OVERALL RATING
o Competent
o Not Yet Competent
Automotive
Assessors Signature________
Trainee Signature________
Date Developed: April
9 2025
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Paint Work NC II
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Christyl Mae R. Vidal
INFORMATION SHEET
Work instructions are also called work guides, Standard Operating
Procedures (SOPs), job aids or user manuals, depending on the situation.
In any case, the purpose of work instructions is to clearly explain how a
particular work task is performed. They’re like the step-by-step instructions
we receive when we learn to drive a car: check gear stick is in neutral, start
the ignition, press the clutch, change to first gear and so forth. This
information sheet will show you how to perform bodywork repair step by
step:
Step 1: Gather Tools Needed/Recommended












Replacement panels
Acetylene Torch’s
Safety gloves
Angle Grinder
Rivet gu
AC welder
Welding rods
Tack hammer
Electric Drill
Various grit sandpapers for each sander (rang from 36 to 1600 grit)
Tack cloth
Putty Knife
Step 2: Preparation
1. Before doing any work make sure all materials and tools are gathered
and organized.
2. Have a clean and well-lit workspace.
3. Be sure to be wearing protective clothing when necessary. (Work gloves,
steel toe boots, long sleeve shirt, pants).
4. Read through instructions prior to doing the work, will make work easier
and more understandable.
Step 3: Selecting Area to Cut / Repair
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Date Developed: April
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Christyl Mae R. Vidal
1. Take a replacement piece of metal and size it up against the car. Making sure it is
flush against the car
2. Trace the outline of this piece onto the car. Grab your Chalk/Sharpie and make a line
on the body of where you want to cut. (The area inside the cut will be removed and
replaced). Note: - If the damage is possible to repair by beat with dolly and hammer not
need to cut to replace the damaged parts
Step 4: Cutting Out the Area to Be Replaced Using Acetylene Torch
(wears hand and eye protection)
1. Open the acetylene tank valve ¼ turn. (Keep between 5-8 psi)
2. Open the oxygen tank valve all the way. (Keep between 25- 40 psi)
3. Open the acetylene valve on the torch until you can hear gas escaping.
4. Place the striker in front of the torch and lite.
5. Open the oxygen valve on the torch until the acquired flame is reached.
6. Cut out the selected area on the car.
7. After the area is cut out, using the angle grinder remove any access paint from the
area you are working on, this clean metal surface will allow welding to occur later on.
Using an Angle Grinder (wear hand and eye protection)
Step 5: Fitting Replacement Piece
1. The replacement piece should be the same size as the piece you just cut out.
2. When adding the new piece, make sure it is flush with the original body.
Step 6: Adding Replacement Piece
1. With the new panels now in place, it’s time to permanently join them to the car.
2. First start with the first of the two replacement panels, the one located closer to the
front of the car.
3. Position this piece precisely where you want it, trying to match the original position of
the old piece on the car.
4. When you are satisfied with the position of the panel, use a few pairs of vice grips
and lock the new panel in place.
5. After the piece is in place be certain to check that everything is lined up correctly;
making sure all body lines and mouldings are correct.
6. Now it is time to permanently attach the replacement panel. This can be
accomplished using an Ox-Acetylene or Arc welder, Drill, Drill bits, Rivet gun, and
Rivets.
Automotive
Date Developed: April
9 2025
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Paint Work NC II
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Christyl Mae R. Vidal
Step 7: Welding?
1. Before beginning welding make sure you are wearing the proper protective clothes
for welding, Pants, long sleeves, welding gloves, and eye/face protection.
2. Go ahead and make your welds along that top edge, making sure to control speed,
spacing, and movement.
3. After completing your welds, go ahead and grind the welds down with your angle
grinder; this should make the welds flush with the body.
Step 8: Riveting
1. Now it’s time to rivet the remaining edges of the new panels to the car.
2. For this you will need your Drill, Drill bits, Rivet gun, and rivets.
3. Rivets will be spaced 2” away from each other.
4. They will run along the bottom edge of the replacement panel, and in the inner wheel
well area of the panel.
5. First mark where u want the rivets to be.
6. Equip your drill with a 3/16” Drill bit.
7. Pre-drill every place you want a rivet to be at.
8. The entire replacement panel should now be completely attached to the car.
Automotive
Date Developed: April
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Christyl Mae R. Vidal
Step 9: Body Filler
1. Open your body filler and put a golf ball-sized amount onto your clean mixing surface.
2. With your wooden mixing stick ready, open up your reactor and squeeze an inch
worth of reactor onto the body filler.
3. Mix until a uniform colour is reached. At this point, you have about 3-5 minutes with
the material before it’s no good to use.
4. Apply with your Plastic applicator evenly over the welds on the panel.
Step 10: Sanding
1. Now with a good buildup of material on the car, it’s time to sand it down to make it
fully blend in.
2. Go ahead and grab a various amount of sandpapers, ranging from 36 to 1600 grit.
3. Also it might be necessary to use sanders, block and hand sanders. For this
particular job, the sanding will be done in that order.
4. While using the bar air sanders apply a horizontal force pushing the sander into the
car. Move the sander in mini X motions while doing the sanding.
5. Repeat this step using higher grit sandpaper.
6. After each pass with higher grit sandpapers the surface should be getting smoother
and smoother.
Automotive
Date Developed: April
9 2025
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Christyl Mae R. Vidal
CARRY -OUT BASIC PANEL REPAIRS
CONTENTS
 Identify types of panel damage and determine repair method
 Use tools and equipment for basic panel repair
 Perform dent removal using basic techniques
 Apply and shape body filler
 Sand and finish repaired areas
ASSESSMENT CRITERIA
1. Accurately names and classifies panel damage (e.g.,, Dents, Creases,
Scratches). Wears appropriate PPE and follows safety protocols consistently.
2. Select the correct hand or power tools for the required repair. Cleans, inspects,
and stores tools in designated areas after use.
3. The work area is clean, and the panel is properly accessed for repair. The panel
surface is kept intact without warping or stretching.
4. The mixture is smooth, consistent, and mixed according to product instructions.
The finished surface is smooth and follows the original shape of the panel.
5. Choose appropriate sandpaper grits and tools. The repaired area is free from
dust, grease and imperfections.
TRAINING MATERIALS AND EQUIPMENT
 Sample damaged panels
 Panel Beating tools (hammers, dollies, etc.)
 Body fillers and application tools
 Abrasives (sandpaper, sanding blocks)
 Personal protective equipment (PPE)
 Workshop with benches, vices, lighting
METHODOLOGY
 Demonstration
 Hands-on workshop activities
 Individual practice
 Group discussion
 Trainer-led instruction
ASSESSMENT METHODS
 Demonstration of practical tasks
 Observation Checklist
 Oral questioning
 Written test (where applicable)
 Portfolio of completed work
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Date Developed: April
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Paint Work NC II
Developed by:
Esclamada, Marven G.
Christyl Mae R. Vidal
SESSION PLAN
Sector: Automotive
Qualification Title: Basic dent removal techniques
Unit of Competency: Perform Automotive Body Repair and Paint Work
Nominal Duration: 4 hours
Module Title: Carry out basic Panel Repairs
Learning Objectives
At the end of the session, the trainees should be able to:
1. Identify types of dents and appropriate repair methods.
2. Select and use the correct dent repair tools.
3. Perform basic dent removal following safety procedures.
Introduction
This module teaches trainees how to repair small dents and damage on vehicle
panels. Trainees will learn how to use basic tools, remove dents, apply body filler,
and prepare the surface for painting.
Learning Content
Method
Presentation
Resources
Introduction and
Review
Lecture, Q and
A
Module,
whiteboard, marker
15mins.
Tool Orientation and
Safety
Demo and
interaction
Facilitate discussion
and connect prior
learning
Demonstrate tool use
and safety practices
30mins.
Dent Removal
Demonstration
Demo
Guide and correct
trainee techniques
Safety goggles,
gloves, masks, tool
checklist
Suction-type dent
pullers
Hands-on practice
Dent removal
Workshop
Observe and provide
feedback
Dent pullers
45mins.
Break
Filler mixing and
application
Hands-on practice,
apply and shape filler
Demonstration
Workshop
Recap and Feedback Discussion and
Q&A
Explain and
demonstrate step-bystep
Supervise, assist and
evaluate
Hammer and dolly
set
Sample damaged
panels
Provide feedback
Time
30mins.
15mins.
30mins.
45mins.
30mins.
Total: 4 hours
Automotive
Date Developed: April
9 2025
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Paint Work NC II
Developed by:
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Christyl Mae R. Vidal
LIST OF COMPETENCIES
A. Basic Competencies
1. Participate in workplace communication
2. Work in a team environment
3. Practice career professionalism
4. Practice occupational health and safety procedures
B. Common Competencies
1. Apply safety practices
2. Use and maintain tools and equipment
3. Prepare materials and tools
4. Perform mensuration and calculation
5. Read, interpret and apply specifications and manuals
6. Perform shop maintenance
C. Core Competencies
1. Remove and install automotive body components
2. Repair minor dents and other surface irregularities
3. Weld automotive body panels
4. Apply body filler and sand repaired surfaces
5. Prepare surfaces for painting
6. Apply automotive paint
7. Polish painted surfaces
8. Perform final detailing and quality check
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Date Developed: April
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Christyl Mae R. Vidal
INFORMATION SHEET
Identifying Body Panels
Body and Frame Construction
A. Body Construction
Bodies: Passenger cars and truck bodies differ a great deal in construction because of
the different purposes for which they are intended. However, each has an inner and
outer construction. The outer construction is considered that portion of a panel or panels
which is visible from the outside of the vehicle. Included in the inner construction are all
braces, brackets, panels, etc. that are used to strengthen the vehicle body. A general
assumption is that inner construction cannot be seen from the outside of the vehicle.
Body Construction:
The main body components are shown in Figure 1.6. Cowl or dash panel assemblies for
the front end of the body are usually formed by assembling several smaller panels.
These are the cowl upper panel and the cowl side panels that are joined by welds into
one solid unit. The cowl extends upward around the entire windshield opening with the
upper edge of the cowl panel forming the front edge of the roof panel. Windshield pillars
are part of the cowl panel.
I. Roof Panel Assembly. The roof panel is one of the largest body panels, but it is also
one of the simplest in construction. Usually, the roof is a one-piece steel construction
II. Floor Pan Assembly: The floor pan(refers to a floor-related component) is composed
of several smaller panels that are welded together or secured to one another by bolts to
form one single unit, as shown in Figure 1. 7. Most floor plans are irregularly shaped.
They are indented or formed into bends to give strength to the entire floor structure.
III. Rear Quarter Panel. The rear quarter panel is an integral part of the fender. The rear
quarter panel
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Christyl Mae R. Vidal
has both inner and outer construction. The outer construction or outer panel is smooth,
except for the breaks caused by the design of the vehicle. The inner construction of a
rear quarter panel is made up of many strong reinforcement brackets welded or bolted
together to form a single unit.
IV. Doors: Doors are composed of two main panels: outer and inner. Both panels are
normally of all steel construction. Doors derive most of their strength from the inner
panel. The inner panel acts as a frame for the door. It is made with offsets and holes for
the attachment of inner door hardware. The outer panel flanges over the inner panel
edges to form a single unit. It also provides an opening through which the outside
handle protrudes. In some instances, a separate opening is provided for the lock.
V. Deck Lid: The deck lid is another door that allows access to the luggage
compartment. It consists of an outer and inner panel. These panels are spot-welded
together along their flanged edges to form a single unit.
B. Frame (Chassis) Construction.
An understanding of the construction of the frame is extremely important since it is the
foundation on which the vehicle is built. Frames can be constructed from channel stock,
Ibeam, angle, Zstock, tubing, flat plates, or a combination of any two or more of these
stocks. Frame/Chassis includes everything under the body, consisting of the
mechanical systems that support and power the car. In general, there are two types of
frame construction for light duty vehicle
I Uni-body construction welds major body panels together to form the frame for
attaching the engine,
drivetrain, suspension, and other parts. This type of construction is commonly used on
cars. Uni-body
construction uses body parts welded and bolted together uses lighter; thinner, highstrength steel
alloys Body shell is formed by welding sheet metal into a box- or egg-like configuration.
li . Body-over-frame construction, a thick gauge steel frame provides the foundation for
holding other parts. This type of construction is commonly used on large trucks and
SUVs. Body-over-frame vehicles have separate body and chassis parts bolted to the
frame vehicle is heavier – high amounts of energy are absorbed by the frame in a
collision Figure 1. 9. Two very different methods used to construct modern vehicles:
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Unibody and body-over-frame construction
1) Fender
2) Rocker panel
3) Roof side rail with centre body pillar
4) Roof panel
5) Quarter panel
6) Tail lamp holder
7) Front bumper sheet
8) Deflector
9) Hood panel
10) Driver door assembly
11) Left rear Door assembly
12) Back door panel (Trunk or Deck Lid)
13) Rear Bumper
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1. Bonnet (Hood) The hood protects your engine and other essential components of
your truck. Whether you have a rusted or damaged hood, repairing/replacing it is often
relatively easy.
2. Bumper / Energy Absorber / Cover Bumpers are located at the front of the vehicle,
below the front grille. They’re intended to be the first thing to hit an object in front of
them (such as another vehicle) and to minimize the impact and damage to the rest of
the vehicle, minimizing repair costs.
3. Radiator Support/ Header panels Header panels are an important part of the body
that provides support and mounting locations for grille assemblies, radiator and
headlights.
4. Grille The front end of the vehicle has seen considerable developments over the past
few years. The principal function of the grille is to admit cooling air to the car's radiator.
5. Headlamp Headlamp Automotive lighting keeps our families safer. In a moment,
drivers must gauge a vehicle's position, size, and direction of travel.
6. Door The complete truck door is made of several components, but this term refers to
the largest panel and shell. A vehicle’s door panel provides attachment points for
handles and often side-view mirrors as well. Areas at the bottom of doors can trap
water, dirt and debris — especially when drain holes get clogged.
7. Guard (Fender) Fenders typically form an arch — made either of plastic or metal —
on the side of the vehicle body, around each of the wheel cutouts. Rotating tires can
throw lots of water, snow or pieces of debris while driving, so fenders help mitigate
some of this matter.
8. Side Panel (Wheel arch panels) Wheel arch panels receive abuse from grime and
salt. These are the panels that sit above and around the truck wheels. They protect the
rest of the body from moisture and debris thrown by your tires, so they often need to be
replaced after years of use. Manufacturers tend to put foam in between the wheel arch
and the inner wheelhouse, to help limit vibration and noise, but this foam holds moisture
and causes both panels to rust.
9 Tail Gate Located at the very back of your truck, there is no end to the ways you can
damage a tailgate. Whether you back into a post in a parking lot or get rear-ended while
sitting in traffic, tailgates are a commonly damaged component of your vehicle.
10 Mirror A rear-view mirror (or rearview mirror) is a flat mirror in automobiles and other
vehicles, designed to allow the driver to see rearward through the vehicle's rear window
11 Roof Panel The roof panel covers the cab of your truck, and you likely don’t give it
much thought most days. Because it is often out of site, you may not notice rust or other
damage to this panel. Even direct sunlight over prolonged periods can damage your
roof p 12. Truck Bed Floor Your truck bed floor takes a beating – from payloads going in
and out, to salt, water and debris that accumulates in it. Your floor is likely made up of
several different panels. Depending on the damage you may be able to only replace
parts of it or certain panels or supports.
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SELF CHECK 01 TYPES OF PANEL DAMAGE
Module: Carry out Basic Panel Repairs
Topic: Identifying Types of Panel Damage
Name:
Date:
Instructions: Choose the correct answer or write your response in the space provided.
1. Which type of damage is most likely caused by hail?
a. Crease
b. Ding
c. Rust
d. Scratch
2. What type of panel damage usually forms a long, sharp line on the surface?
3. True or False: Rust damage can be ignored if the vehicle is not driven often.
4 Which of the following is least likely to be repaired using a suction puller?
a. Small dent
b. Large crease
c. Shallow ding
d. Round dent
5. Why is it important to assess panel damage before repair?
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Christyl Mae R. Vidal
SELF-CHECK 02 BASIC TOOLS IN DENT REPAIR
Module: Carry out Basic Panel Repair
Topic: Tools and Equipment
Name:
Date:
Instructions: Match the tool with its correct function. Write the letter of the correct
answer.
Tools:
A. Hammer and Dolly
B. Suction Puller
C. Sanding Block
D. Body Filler
E. PPE (Personal Protective Equipment)
No.
Function
1
Used to apply filler smoothly
2
Remove minor dents without damaging the
paint
3
Keeps sanding surface even
4
Required to protect worker from hazards
5
Used to push and shape metal back into place
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Answer
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SELF-CHECK 01 TYPE OF PANEL DAMAGE
ANSWER KEY!
Answer:
1. b. Ding
2. Crease
3. False
4. b. Large crease
5. To determine the right repair method, avoid wasting time and materials, and
ensure safety and quality in the repair
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Christyl Mae R. Vidal
SELF CHECK 02: BASIC TOOLS IN DENT REPAIR
ANSWER KEY!
Answer:
1. D
2. B
3. C
4. E
5. A
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JOB SHEET 02
Module Title: Carry out Basic Panel Repairs
Job Title: Applying and Sanding Body Filler
Trainee Name:
Trainer/Assessor
Date:
OBJECTIVES:
To apply body filler to a prepared panel surface and sand it to match the panel contour
TOOLS AND MATERIALS







Body filler and hardener
Mixing board and spreader
Sandpaper (80, 180, 320, grit)
Sanding block
Wax and grease remover
Clean cloth
PPE (gloves, dust mask, eye protection)
PROCEDURES
A. Application of Filler
Ensure the panel is clean and free of grease or rust.
Mix filler and hardener as per manufacturer's ratio.
Apply filler evenly over the repaired area using a plastic spreader.
Allow the filler to cure for the recommended time.
B. Sanding
Begin shaping with 80-grit sandpaper using a sanding block
Smooth the filler surface with 180-grit sandpaper.
Finish with 320-grit for a refined surface.
Clean and inspect for surface imperfections.
JOB COMPLETION CHECKLIST
Task
Completed ()
Panel cleaned before application
Correct mixing ratio used
Filler applied evenly
Filler sanded to correct contour
Tools cleaned and PPE used properly
Trainers Comments:
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JOB SHEET 01
Module Title: Carry Out Basic Panel Repairs
Job Title: Removing a Small Dent using Hammer and Dolly
Trainee Name
Trainer/Assessor:
Date
OBJECTIVE:
To safely and effectively remove a small dent from a vehicle panel using a hammer
and dolly.
TOOLS AND MATERIALS
•
•
•
•
•
•
Body hammer
Dolly block
Panel cleaning solution
Masking Tape
Marker or chalk
PPE (gloves, ear protection, safety glasses
PROCEDURE
A. Preparation
Wear all required PPE.
Clean the damaged panel using a cleaning solution.
Mark the area of damage.
Choose the correct hammer and dolly pair based on the panel shape.
B. Dent Removal
Position the dolly behind the dented area.
Gently tap around the dent using the hammer while supporting it with the dolly.
Gradually move toward the centre of the dent until it is flush with the panel.
Inspect the repaired area for uniformity
JOB COMPLETION CHECKLIST
Task
Completed()
PPE worn at all times
Dent located and marked properly
Correct tools selected
Dent removed evenly
Tools cleaned and returned
Trainer Comments:
Automotive
Date Developed: April
9 2025
Page
Checked by:
Body Repair and
Paint Work NC II
Developed by:
Esclamada, Marven G.
Christyl Mae R. Vidal