ASE Practice Test (B3: Non-Structural Analysis & Damage Repair) 2 — Questions and Answers
Question 1: When repairing a dent in a steel panel using the "hammer-off-dolly" technique, where is the dolly placed?
- Directly under the hammer strike location
- Adjacent to the hammer, positioned beside the high spot to raise metal around the area (Correct answer)
- On the outside of the panel
- Under a low spot while hammering a separate high spot
Correct answer: Adjacent to the hammer, positioned beside the high spot to raise metal around the area
The hammer-off-dolly technique positions the dolly alongside (not directly under) the dent. The hammer strikes the high spot while the dolly provides upward support and pressure on the adjacent low area. This combination drives the high down and pushes the low up simultaneously, gradually working the metal back to its original contour. This is contrasted with the hammer-on-dolly technique for planishing.
Question 2: Which type of plastic repair requires a two-sided repair using a backing patch on the inside of the panel?
- Minor surface scratches on thermoplastic olefin (TPO)
- A structural crack or tear that goes completely through the plastic panel (Correct answer)
- Painting adhesion promotion on unpainted bumpers
- Surface gouges less than 1mm deep
Correct answer: A structural crack or tear that goes completely through the plastic panel
A complete crack or tear through a plastic panel requires structural reinforcement from both sides. A backing patch (made of fiberglass cloth or plastic repair mesh bonded with adhesive) is applied to the inside (hidden) surface first to hold the panel shape. Filler adhesive is then applied to the outside to restore the surface contour. Single-sided repair of full-thickness cracks will fail under stress.
Question 3: After a minor fender repair, panel gaps appear uneven — the fender is too close to the door at the top and too far at the bottom. What adjustment is needed?
- Loosen all fender bolts and push the entire fender toward the door
- Adjust the upper rear fender mount to move the top of the fender away from the door (Correct answer)
- Replace the fender with a new OEM part
- Add shims to all fender mounting points
Correct answer: Adjust the upper rear fender mount to move the top of the fender away from the door
Uneven panel gaps require targeted adjustments. If the fender is too close at the top and too far at the bottom, rotating the fender — moving the top away from the door — will correct both conditions simultaneously. Most fenders have slotted mounting holes that allow in/out and up/down adjustments independently at each mounting point.
Question 4: What is the purpose of a "flex additive" when painting plastic bumper covers?
- It accelerates the drying time of the topcoat
- It makes the paint film flexible so it can expand and contract with the plastic without cracking (Correct answer)
- It improves hiding power of the basecoat on dark plastics
- It prevents the paint from running on vertical surfaces
Correct answer: It makes the paint film flexible so it can expand and contract with the plastic without cracking
Plastic bumper covers flex during minor impacts and temperature changes. Without a flex additive, the cured paint film (which is more rigid than the plastic substrate) will crack or chip when the bumper flexes. Flex additive is mixed into primer and/or topcoat to give the paint film the elasticity needed to move with the bumper without cracking.
Question 5: Which tool is used to measure the straightness of a repaired panel surface for low spots that cannot be seen visually?
- Body spoon
- Long rigid straightedge or 36-inch rule (Correct answer)
- Slide hammer
- Spotweld drill bit
Correct answer: Long rigid straightedge or 36-inch rule
A long metal straightedge (often 36 inches or longer) is placed across a repaired panel in multiple directions to detect high and low spots that are invisible to the eye. Light between the straightedge and the panel reveals low spots; areas where the straightedge rocks indicate high spots. This technique is used before and during filler application to ensure panel straightness.
Question 6: A technician is using a stud welder and slide hammer to pull out a dent. After pulling the studs, the remaining small craters left by the studs should be treated how?
- Filled with body filler immediately without any metal finishing
- Metal finished with a hammer and dolly to planish the high rings around each stud location, then apply minimal filler (Correct answer)
- Ground flush with an angle grinder only
- Left as-is since filler will fully cover them
Correct answer: Metal finished with a hammer and dolly to planish the high rings around each stud location, then apply minimal filler
Stud welding and pulling leaves small raised rings of metal around each stud location. These high rings must be planished flat using a hammer and dolly before applying filler. Applying filler over high metal rings creates a wavy surface. Metal finishing to a near-perfect contour minimizes filler thickness, which improves the durability and adhesion of the repair.
ASE Practice Test (B3: Non-Structural Analysis & Damage Repair) 2
When repairing a dent in a steel panel using the "hammer-off-dolly" technique, where is the dolly placed?