NCT Manual. - National Car Testing Service

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BODYWORK
NATIONAL CAR TEST (NCT) MANUAL 2012
Method of Testing
Examine primary structural components (including floor pan) for cracks, security, damage or rust. Check where repairs have
been carried out that there is an engineer’s report stating that the original strength and safety of the vehicle has not been
compromised and that any welding or brazing has been carried out using good engineering practice. Check from both front and
rear that the body is sitting squarely. Examine all secondary structural components for security, rust or jagged edges. Check that
bumpers, guards and body panels are secure and not likely to injure pedestrians or other road users.
Check that fumes are unlikely to enter the vehicle e.g. torn gear lever boots.
Check that the bonnet and boot lid catches are operating properly. In the case of front opening bonnets, ensure that the safety
catch is fitted and operating properly.
Primary Structure
1. Primary structure includes any structure or component which, if it collapsed, would make the vehicle uncontrollable or would
considerably reduce occupant safety in the event of an accident. Examples of components in this category are illustrated on
page 57. Areas within 100mm of door locks or hinges would be considered primary structure.
Secondary Structure
2. Secondary structure includes any structure or component which, if it collapsed, would not immediately affect a vehicle’s
controllability or the protection provided by its built-in safety systems. Normally, rust would not be a cause for rejection in
these components but extensive rust is usually either hazardous to persons in or near the vehicle because of its sharp edges or
because exhaust fumes can get into the vehicle. Extensive rust must therefore be rejected. The illustration on page 57 shows
examples of secondary structure.
NOTES
1. A missing or damaged mud flap is not a reason for failure.
2. The judgement to be made is whether or not the manufacturer’s original strength has been maintained.
Where a manufacturer has used brazing in some area of the manufacturing process, repairs using a
similar process and to a similar standard of workmanship is acceptable. Using brazing to repair chassis
members is not acceptable.
3. Where a boot is completely full, an examination cannot be made and therefore a pass certificate cannot
be issued.
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