Collision Repair Quality Control Final Inspection Checklist

This collision repair quality control checklist provides a comprehensive post-repair inspection covering all aspects of collision restoration including panel fit and alignment, paint quality, structural verification, ADAS calibration, and mechanical systems. Aligned with I-CAR Professional Development standards, OEM collision repair documentation requirements, and insurer quality audit protocols. Complete this inspection before every vehicle delivery to ensure safe, quality repairs and customer

Industry: Automotive Body Shop
Frequency: Per Completed Repair / Pre-Delivery
Estimated Time: 30-45 minutes
Role: Quality Control Inspector / Shop Foreman / I-CAR Gold Class Technician
Total Items: 28
Compliance: I-CAR Professional Development Quality Standards, OEM Collision Repair Procedures and Tolerances, ICAR ProFirst Shop Certification Standards, Insurer Quality Repair Standards (State Farm, Allstate, GEICO etc.), OSHA 29 CFR 1910.94 (Spray Finishing)

Panel Fit & Alignment

Verify all repaired and replaced panels meet OEM gap and flush tolerances. Gap inconsistency is the most visible indicator of quality.

All panel gaps consistent with OEM specification (typically 3-5mm, uniform side-to-side)?
All panels flush (even surface level) with adjacent panels - no surface high/low spots?
All doors open, close, and latch correctly without force or adjustment?
Hood and trunk/tailgate aligned correctly with consistent gaps and latch without effort?
No excessive body filler visible through paint (sand-through, pinholes, or sanding scratches)?

Paint Quality & Finish

Paint quality inspection under proper lighting. Most customer complaints involve paint quality.

Refinished panel color matches adjacent panels in daylight and under shop lighting?
Paint free of runs, sags, fisheye, dirt, or orange peel exceeding OEM texture?
Blended panels transition invisibly into adjacent panels without visible blend line?
Clear coat applied with uniform gloss and adequate film build?
No paint overspray on glass, trim, rubber seals, or adjacent unrepaired panels?
No masking lines visible on trim, moldings, or glass?

Structural & Mechanical Systems Verification

Verify all structural, mechanical, and safety systems are correctly restored after collision repair.

Post-repair full system diagnostic scan completed - no unresolved codes?
All ADAS systems requiring calibration completed with calibration reports?
Wheel alignment performed and vehicle aligns to OEM specification?
Steering wheel centered on straight and level road?
All affected seatbelts (pre-tensioners, load limiters) replaced if deployed or loaded in collision?

Detail & Cleanliness

Vehicle must be clean and presentable at delivery. Post-repair detail is part of quality delivery.

Interior cleaned of all repair debris, dust, and overspray?
Exterior hand-washed and windows cleaned inside and out?
No compound or polish residue remaining in trim gaps or on rubber?
All protective film and masking tape completely removed from new parts?
Undercoating or anti-corrosion treatment applied to welded/replaced structural areas?
All emblems, badges, and trim clips replaced (not reused from damaged parts)?

Delivery Documentation & Customer Communication

Complete all documentation and prepare for thorough customer delivery.

Post-repair photos taken showing completed work quality?
All calibration reports, scanning reports, and measuring documents in repair file?
Written repair warranty prepared per shop policy (typically limited lifetime paint warranty)?
Customer delivery walkthrough completed - all repairs explained?
Customer satisfied with repairs and signed delivery authorization?
Follow-up call scheduled 3-5 days after delivery to confirm satisfaction?

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Why Use This Collision Repair Quality Control Final Inspection Checklist?

This collision repair quality control final inspection checklist helps automotive body shop teams maintain compliance and operational excellence. Designed for quality control inspector / shop foreman / i-car gold class technician professionals, this checklist covers 28 critical inspection points across 5 sections. Recommended frequency: per completed repair / pre-delivery.

Ensures compliance with I-CAR Professional Development Quality Standards, OEM Collision Repair Procedures and Tolerances, ICAR ProFirst Shop Certification Standards, Insurer Quality Repair Standards (State Farm, Allstate, GEICO etc.), OSHA 29 CFR 1910.94 (Spray Finishing), EPA 40 CFR Part 63 Subpart HHHHHH (Refinishing), UK BS 10125:2022 Vehicle Body Repair Standard. Regulatory-aligned for audit readiness and inspection documentation.

Frequently Asked Questions

What does the Collision Repair Quality Control Final Inspection Checklist cover?

This checklist covers 28 inspection items across 5 sections: Panel Fit & Alignment, Paint Quality & Finish, Structural & Mechanical Systems Verification, Detail & Cleanliness, Delivery Documentation & Customer Communication. It is designed for automotive body shop operations and compliance.

How often should this checklist be completed?

This checklist should be completed per completed repair / pre-delivery. Each completion takes approximately 30-45 minutes.

Who should use this Collision Repair Quality Control Final Inspection Checklist?

This checklist is designed for Quality Control Inspector / Shop Foreman / I-CAR Gold Class Technician professionals in the automotive body shop industry. It can be used for self-assessments, team audits, and regulatory compliance documentation.

Can I download this checklist as a PDF?

Yes, this checklist is available as a free PDF download. You can also use it digitally in the POPProbe mobile app for real-time data capture, photo documentation, and automatic reporting.