176 Section 2 Nonstructural Repairs
Copyright Goodheart-Willcox Co., Inc.
Easily replaced, low-cost panels, such as fenders,
are often replaced if they have more than minor
damage. A quarter panel, which is relatively expen-
sive and time-consuming to replace, will generally be
repaired even when moderately damaged.
Another consideration when determining whether
a panel should be repaired or replaced is the ease
of repair. The ease of repair is directly related to the
cost of repair. Low-crown panels, such as hoods and
roofs, may be replaced rather than repaired if they
are damaged. Repairing a damaged low-crown panel
would be difficult and time-consuming. This is espe-
cially true if the hood is aluminum. A low-crown panel
is more difficult to repair than a high-crown panel.
Figure 9-4 shows a damaged quarter panel. The
metal is torn and there is no access to the back of
the panel. Alignment of the torn edges would not be
possible. Therefore, the panel should be replaced.
Longitudinal force on a body line may cause two
or more buckles to form at a pivot point, such as an
internal brace. These buckles, which are referred to
as a double fold, are close together. The metal in
the double fold is work hardened, both by the panel
forming process and by the damage resulting in
buckles. When sheet metal is severely damaged in
this way, the folds are so hard that straightening would
be difficult. Heat could be applied to the folds while
pulling, but the customer would be better served by
replacing the panel.
Similarly, internal brace damage is generally not
repaired. Figure 9-5 shows a damaged hood. The
internal hood braces are bent, and there are double
folds in the metal at the edge of the hood. Because the
brace is attached to the hood skin, the inside of the
brace is not accessible. Repair is not practical, and the
hood should be replaced.
Planning the Repair
Planning involves thinking through each step in
the repair process. Think of a plan as a road map. Can
you reach a destination without a map? Maybe, but
you could end up backtracking. A technician who can
analyze and plan will prevent wasteful backtracking
when making repairs.
To repair panel damage caused by longitudinal
force, the panel’s length must be restored. To repair
damage caused by lateral force, not only must the
length be restored but the surface area may also have
to be changed. In both situations, buckles must be
released. In most types of damage, the panel length
should be restored first, and then the buckles can be
released.
Your ability to plan will increase with experience.
Always take the time to devise a plan before starting a
repair. As you develop your plan, you must:
■ Identify obstructions to be removed (emblems,
moldings, handles, etc.).
■ Determine if access to the back side of a panel is
necessary and, if so, decide how to access the
back side of the damage.
■ Determine what tools are needed to make the
repair.
■ Determine the sequence of basic operations.
■ Make sure the shop equipment required for the
repair will be available when needed.
■ Determine if an assistant is required to make the
needed repairs.
■ Make sure all the required materials are on hand
(sandpaper, filler, etc.).
Goodheart-Willcox Publisher
Figure 9-4. This quarter panel was torn open during a
collision. The panel is not repairable.
Goodheart-Willcox Publisher
Figure 9-5. The internal structure of this hood was
damaged during a collision with another vehicle.
Therefore, the hood should be replaced.
Tear
Internal brace Double fold