178 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.). • Decide which buckles will be worked first. • Identify the area that will be filled. • Determine how long the repair will take. Goodheart-Willcox Publisher Figure 9-4. The dogleg portion of the quarter panel was torn in a collision. 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. Internal brace Double fold