Panel Repair Techniques and Dent Removal
What this domain tests
This domain tests damage assessment and metal repair, including paintless dent repair (PDR), hammer-and-dolly work, shrinking, and heat limits. The exam tests whether you can choose a method that preserves panel strength and finish.
Core rules
- Assess direct and indirect damage; check panel access, backside reinforcement, and whether the paint is cracked.
- PDR suits gradual dents with intact paint and backside access; sharp creases, stretched metal, or cracked paint need conventional repair or replacement.
- Use hammer-and-dolly to restore contour, then shrink stretched areas carefully; avoid overworking the metal.
- Follow OEM heat limits; many high-strength panels cannot be heated for straightening.
- Use aluminum-specific tools on aluminum to avoid galvanic contamination; clean before filler or refinish.
Worked example
A hail dent is in an aluminum hood with intact paint. The technician uses PDR with aluminum tools and gentle pressure, checking the contour with a profile gauge. Reasoning: steel tools can embed steel particles and cause galvanic corrosion, and heating aluminum can alter properties; PDR preserves the finish if the dent is gradual and accessible.
Traps
Using PDR on a sharp crease or stretched metal; heating AHSS/UHSS to shrink; using steel tools on aluminum; applying filler over rust or cracked paint; ignoring backside damage.