Metal Panel Repair and Replacement
Metal Panel Repair and Replacement
This domain covers metal panel repair techniques (hammer and dolly, stud welding, shrinking) and replacement procedures (cutting, welding, panel bonding). You must know when to repair vs. replace: repair is suitable for minor dents and creases, while replacement is needed for severe damage, creased edges, or high-strength steel areas that cannot be repaired. Traps include using heat on HSS (which weakens it), improper welding techniques (e.g., using oxy-acetylene on modern panels), and neglecting corrosion protection after welding. Also, understand panel bonding (adhesive) and rivet bonding as alternatives to welding. Worked example: A dent in a door skin with stretched metal requires shrinking (using a torch or shrinking hammer) before filling; otherwise, the filler will crack. Rule of thumb: Never heat HSS above 400°F (204°C) unless specified by the manufacturer; use a heat-indicating method. Key concepts: hammer and dolly, stud welder, shrinking, panel bonding, weld-through primer, HSS repair restrictions, corrosion protection.