need expert help - how to not scratch the paint

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eddiew

need expert help - how to not scratch the paint

Post by eddiew »

I work at a car factory. About 20 cars per day are needing a piece of glass replaced. Many times it's the windshield. The problem is almost every time the guy scratches the paint badly and it ends up going to paint repair and costs the factory more money. He is using a regular cold knife and many times uses an air powered knife which is horrible for the paint. He says it's unavoidable because the urethane has dried so much or the gap between the metal and the windshield is too small (sometimes it really is and that's why it's being replaced). Also sometimes the window is scratched. The cars are new Pontiac Vibes and Toyota Corollas. Any tips, tricks, techniques, tools, etc on how to avoid scratching the paint while removing any of the windows would be greatly appreciated!
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Brent Deines
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Re: need expert help - how to not scratch the paint

Post by Brent Deines »

Is the paint being scratched in a place that is visible after the replacement is completed, or just on the pinch weld that can be painted and covered with the new glass and moldings?

I can understand how it would be difficult not to scratch the pinch weld when removing a very tight windshield, but there is no excuse for scratching the paint in an area that will be visible when the job is complete.

I am no longer in the replacement business, but there are a number of great removal tools on the market these days. In helping my son remove a very tight windshield last year I ended up going old school and used a piece of piano wire to cut out the windshield because my cold knife and power tools just weren't cutting it. In your case you might look into using an induction heater to remove the glass. I have heard mixed reviews about these tools, but the demos are pretty impressive. I'm sure there are other companies with similar products, but this is the one I saw. http://www.autotronheater.com/default.asp?ID=10 I don't think you are going to win any speed contests with an induction heater, but if it saves the paint it may be worth considering.

In any case, the skill level of technicians varies greatly, so I think I would be looking for new replacement technician if he cannot figure out a way not to scratch the paint.
Brent Deines
Delta Kits, Inc.
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eddiew

Re: need expert help - how to not scratch the paint

Post by eddiew »

Thank you for your response, Brent.

The scratches appear both on the pinch weld and on the visible paint. I will look into the wire tool - they may already have one lying around somewhere. As for the induction tool, that looks like a great idea, though I would rather the technician be able to do it the way everyone else does it.

Does not scratching the paint simply come down to having patience? Is there a tape or something out there that effectively prevents scratching?
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Re: need expert help - how to not scratch the paint

Post by Brent Deines »

I will use a removable masking tape around the corners or anywhere I think there may be a possibility of scratching, but really it just comes down to being very careful. Any removal tool will go through tape too, so although it may help, the only way to avoid scratches is to keep the tool from going outside the area that will be covered by the glass and moldings.

I'm not saying it is easy, it's not, but with proper tools and a good technician scratching should be a rare occurrence indeed. I did a lot of work for high end new car dealerships that would at times have glass broken in new cars while still on the lot, and I can assure you that scratching was not an option for us. Not once did we have to have a new car visit the paint shop after one of our installations.
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I102bs

Re: need expert help - how to not scratch the paint

Post by I102bs »

Hi, Cold knives work best when the blade is sharp and a lubricant is used. The knives come with replaceable blades with different lengths so you can make an initial light cut and then follow it up with a longer blade or blades. You can also cut the urethane from the inside with a long razor knife. Equilizer is a company that makes powered and unpowered cut out tools among other things. they have a square shaped "piano" wire and sell handles that attach to the wire. That speeds things along. Your tech needs training and perhaps some motivation. Paint scratches other than to the pinch weld should be rare. If you cut where it is not tight you may well be able to pull the glass sideways and stretch the uncut urethane and widen the gap. Perhaps management could hire a local glass replacement company to analyze and train if needed. They might even farm that work out and cut costs substantially. Good luck!!
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Re: need expert help - how to not scratch the paint

Post by Glasseye »

I think you may be missing the point here. The question is why is the glass being scratched? If your fitting a scratched glass then you need to look at your quality inspection procedure. If the glass is being scratched during assembly then you need to establish what are the causes and deal with them.
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eddiew

Re: need expert help - how to not scratch the paint

Post by eddiew »

You make a good point. Eliminating all sources of the scratches would be our best bet. There are also several other types of mistakes that can happen here that warrant window replacement. As long as we have humans building the cars, we will have a glass repair station. The problem I am trying to find a solution to here is our glass repair tech scratching the exterior paint.
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Re: need expert help - how to not scratch the paint

Post by freightshaker »

Just a thought here.

If he's wearing a watch or ring and his wrist hits the hood, he'll scratch it. If he's wearing pants (I hope so) and leans up against the car at any time, you can guarantee a scratch will be left there, too, from the button on his pants rubbing the car. These are the same sorts of problems we have to watch out for in windshield repair.
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Re: need expert help - how to not scratch the paint

Post by Glasseye »

Regarding glass removal, the least scratch risk removal system would be using a square section wire butthe fitter will need expert training in the use of this system and it may still require 2 persons. Regarding curing the production problems I have studied Edward Demming and I feel sure that employing some of his ideas would cure the problem. It certainly did for the Japanese.
Is a customer always right? - No, but they are always the customer.
eddiew

Re: need expert help - how to not scratch the paint

Post by eddiew »

I agree with you completely. I believe a long, in depth project to eliminate the sources of glass defects would yield results that far outweigh having a top notch repair station. I hope that one day the management will agree :smile:

Regarding the expert training for using the square section wire, would you suggest calling a glass specialist that uses this tool and hiring him to do the training?

Employees here are required to wear protective gear over watches, rings, belt buckles, etc. The paint damage I am talking about is definitely from the removal tools, as I have witnessed it happen.

Thank you for all your replies so far!
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