EVS REQUIRE NEW SAFETY AND WORKFLOW APPROACHES —HERE’S THE ESSENTIAL EQUIPMENT FOR CERTIFIED SHOPS
Electric vehicles are now a steady part of the collision repair mix. Shops stepping into EV work quickly learn that the risk profile, tooling and workflow are different. High-voltage systems, integrated battery structures and mixed materials demand tighter processes and the right equipment. This guide outlines essential tools used by EV-certified bodyshops, with consistent, practical detail for each
3M Panel Bonding Adhesive is a two-part epoxy designed for joining metals and composites in modern vehicle construction. It is approved by many OEMs and is often specified where welding is not recommended. The adhesive contains glass beads that help maintain consistent bond-line thickness while also providing corrosion protection between panels. This allows technicians to achieve repeatable results when bonding structural components such as quarter panels or roof skins.
3mcanada.ca/3M/en_CA/p/d/b40066467
MODERN EVS RELY ON MIXED MATERIALS LIKE ALUMINUM AND COMPOSITES, MAKING HEAT-FREE BONDING SOLUTIONS LIKE 3M PANEL BONDING ADHESIVES ESSENTIAL FOR SAFE, CORROSION-RESISTANT REPAIRS.
The Car-O-Tronic® with Vision2™ software from Car-O-Liner® measures vehicle structures in real time using electronic sensors. According to the company, it integrates with a vehicle database to provide reference points and guide technicians through repairs. Measurements can be taken throughout the repair process, allowing technicians to monitor progress and reduce rework. This approach improves accuracy and efficiency across structural repairs. Modern electric vehicles have specialized structural designs (e.g., high‑strength alloys, battery enclosures, unique frame dimensions) that require precise and accurate measurement before and after repairs to ensure safety and performance. Tools like Car-O-Tronic® with Vision2™ help technicians meet those needs.
car-o-liner.com/product/car-o-tronic
EVS HAVE UNIQUE STRUCTURES— HIGH‑STRENGTH ALLOYS, BATTERY ENCLOSURES, AND SPECIAL FRAMES— THAT DEMAND PRECISE MEASUREMENTS, AND CAR‑O‑TRONIC WITH VISION2 HELPS TECHNICIANS GET IT RIGHT.
Using camera-based technology, the HawkEye Elite from Hunter Engineering measures alignment angles and compares them with OEM specifications. The system captures camber, caster and toe quickly while guiding technicians through adjustments. Electric vehicles often carry significant battery weight low in the chassis. After a collision, even small shifts can affect suspension geometry and vehicle handling. Alignment systems provide a measurable way to confirm that repairs have restored the vehicle to proper specifications. In EV repair environments, accurate alignment checks are a routine part of verifying that structural and suspension work has been completed correctly and consistently before delivery.
collisionrepairmag.com/15771715
PULL WITHOUT HEAT — KECO L2E GLUE PULL SYSTEM
The KECO L2E glue pull system uses specialized tabs and controlled tension to repair dents without welding or excessive heat. According to the company, the process helps preserve coatings and reduce invasive repair methods. Technicians apply pulling force gradually, allowing for controlled correction of panel deformation. The system includes multiple tools and tab designs to suit different materials and shapes. This method is particularly useful on electric vehicles, which often use aluminum and mixed materials. Heat-based repairs may not be suitable in these cases. Glue pull repair helps retain original panels and reduce the need for replacement parts.
collisionrepairmag.com/15735668
RESCUE ELECTRIC SHOCK — INSULATED RESCUE HOOK
The insulated rescue hook is designed to pull a technician away from an energized component during an electrical incident. It is made from non-conductive materials and rated for high-voltage environments. The tool is typically wall-mounted in EV work areas and kept visible for quick access. It is intended for emergency use only.
gradeatools.com/insulated-rescue-hook-for-electric-vehicle-repairs-4-1/2-foot/
AN INSULATED RESCUE HOOK SAFELY PULLS A TECHNICIAN FROM HIGH-VOLTAGE DANGER IN AN EMERGENCY.
SHIELD HIGH VOLTAGE — CLASS 0 INSULATED GLOVES
Class 0 insulated gloves are designed for work around systems up to 1,000 volts AC. They are typically worn with leather protectors to prevent cuts and abrasion. Technicians are expected to inspect and test gloves regularly to ensure they remain safe to use. Even small defects can compromise protection.
automation.honeywell.com/us/en/products/personal-protectiveequipment/ electrical-safety/electrical-protection-gloves/class-0- electrical-insulating-rubber-gloves
CONTROL SERVICE DISCONNECT — MSD LOCKOUT DEVICE
The MSD lockout device prevents accidental reconnection of a vehicle’s service disconnect during repairs. It physically blocks the disconnect port and can be secured with a padlock. This ensures that high-voltage systems remain de-energized while technicians are working. Warning tags can also be applied. The device provides a simple but effective safety control.
prosol.co.uk/product/isolation-port-lockout-device-msd/
Safety barrier kits are used to mark EV work zones and restrict access to authorized personnel. The one from Icon Autocraft includes cones, posts and warning signage. Clear visual boundaries help prevent untrained staff from entering areas where high-voltage work is underway. Establishing a dedicated EV zone is recommended in many training programs. Barriers support safer shop operations.
iconautocraft.com/ev-safety-tools-andkits. html
CLEAR VISUAL BOUNDARIES HELP PREVENT UNTRAINED STAFF FROM ENTERING AREAS WHERE HIGH-VOLTAGE WORK IS UNDERWAY.
Built for modern vehicles, the ADS 525X from Bosch is designed to perform full-system scans, live data monitoring and bi-directional testing across a wide range of platforms, including electrified vehicles. According to Bosch, the tool provides access to detailed system data needed during repair and verification. In collision environments, scan tools are used before teardown and again before delivery. With EVs, they also help monitor battery status, identify fault codes and reset systems affected by impact damage. As vehicle electronics become more complex, diagnostics become central to repair workflows. For EV work, scan tools provide the confirmation needed to ensure that systems are operating correctly before the vehicle is returned to the customer.
boschdiagnostics.com/products/ads- 525x-diagnostic-scan-tool?v=18028
LIFT HEAVY BATTERIES — BENDPAK EVS4500
Featuring a low-profile scissor design, the Mobi-EVS from BendPak is intended to support safe removal and installation of EV battery packs in collision repair environments. According to the company, the unit is rated to roughly 4,500 lb., covering most passenger electric vehicle battery assemblies currently in service. The platform uses a battery-powered hydraulic system combined with adjustable saddles that help stabilize uneven loads during removal. Shops can move the unit between bays, which is useful when EV work is not yet dedicated to a single area. Adapters allow technicians to support different battery shapes securely. Controlled lifting reduces risk to both technicians and battery packs while improving consistency across the repair process.
bendpak.com/catalogsearch/result/?product_list_ order=relevance&q=EVS4500
PROTECT AGAINST VOLTAGE — WIHA INSULATED EV TOOL KIT
Designed for high-voltage service work, the Wiha insulated EV tool kit provides technicians with a dedicated set of hand tools intended for use around energized systems. Each tool is individually tested to 10,000 volts and rated for use up to 1,000 volts AC. The kit includes insulated screwdrivers, pliers and sockets organized in a protective case to keep them separate from standard shop tools. Insulated tools are a baseline requirement in most OEM programs. For bodyshops entering EV repair, they are one of the simplest and most effective ways to reduce electrical risk while maintaining proper procedures.
wihatools.com/products/26-piece-insulatedhybrid- ev-essentials-tool-kit
INSULATED TOOLS ARE AN OEM BASIC AND A SIMPLE WAY TO REDUCE EV ELECTRICAL RISK.
