192 Section 2 Nonstructural Repairs Copyright Goodheart-Willcox Co., Inc. Roughing out Specific Types of Damage This section details the procedures for roughing out specific types of damage. Roughing can be performed as a one-sided repair or a two-sided repair. In a one-sided repair, only the outside of the panel is worked. This type of repair is performed when the damaged panel is boxed, such as a quarter panel in front of the rear wheel, or if accessing the back side of the panel is difficult or time consuming, such as a door panel. In a two-sided repair, both sides of the panel are worked. Access to the back side of the panel is required in a two-sided repair. An example of a two- sided repair is damage to a quarter panel behind the rear wheel. In this example, the back of the panel is accessible through the trunk. Keep the following points in mind when reading this section: • If an internal brace or frame rail is damaged, it must be straightened before the panel is roughed out. Braces are strong and will resist the corrective force applied to the damaged panel. • If a change in length is present, the panel must be lengthened. As the length is restored, the buckles can be released. • Buckles must be released before displaced metal is raised. • The metal in buckles and displaced metal belongs somewhere. The purpose of roughing is to move the metal to the right location. Dents Dents are caused by lateral force on low-crown panels. When repairing a dent, care must be taken to prevent stretching. Additionally, shrinking may be required. The following sections, will explain how to make several types of dent repairs. One-Sided Repair, No Body Line In this type of repair, roughing will prepare the panel for filler. Low areas less than 1/8″ (3.2 mm) deep will be left in the repair area. The procedure for one- sided raising of a dent and exposing bare metal is as follows: 1. Raising—Use a DA sander to remove the paint from the low area. A grinder would produce too much heat. Weld a draw pin to the lowest part of the dent and use a T-puller to pull up the low area. See Figure 9-41. Because the damage in this example is small, a slide hammer is not needed. Do not pull too hard, or the damaged area will be raised too much. To raise larger areas, use multiple pins and a slide hammer. 2. Leveling—As the draw pin is pulled up, tap the high area around the low area with a dinging hammer. The draw pin supports the low area, taking the place of a dolly. As the high area is tapped down, the low area is brought up. 3. Shrinking—To prevent chasing the dent across the panel, use a sharp pick hammer to create a shrink fence around the area to be filled. The procedure for one-sided dent raising with a painted panel is: 1. Raising—Glue an attachment to the lowest area of the dent. Pull the attachment to bring the metal to the proper height. See Figure 9-42. 2. Leveling—With the dent at the proper height, tap around the attachment to lower any high spots. Remove the attachment by treating the glue with alcohol. Block sand the area of the dent with 400-grit sandpaper. If no highs or lows are found, the area is ready for refinishing. Goodheart-Willcox Publisher Figure 9-41. As the T-puller applies tension, the hammer lowers a high spot. KECO Body Repair Products Figure 9-42. The glued-on attachment raises a low spot.