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Module 1D2
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  1. Module 1D2 Straightening Damaged Metal

  2. Repairing Damaged Metal – Guidelines • Identify direct and indirect damage • Remove damaged parts, trim, undercoatings and sound deadening material • Clean panel with soap and water, then wax/grease remover • Select proper tools to straighten dent • Constantly check progress of the repair

  3. Repairing Damaged Metal – Locating Damage • Check damage by using glare • Check for high/low spots by feel • Use a thin glove or rag to improve feel

  4. Repairing Damaged Metal – Using Chalk to Locate Low Areas • Rub the area with chalk held lengthwise • Low areas remain uncoated with chalk

  5. Repairing Damaged Metal – Using a Hacksaw Blade to Locate Low Areas • Scrape damaged area with teeth of the blade • Low areas will not be scratched

  6. Repairing Damaged Metal – Using a Body File to Locate Low Areas • Scrape damaged area with body file • Low areas will not be scratched • Don’t use for grinding excess metal • Don’t overfile because newer panels are thin

  7. Repairing Damaged Metal – Using a Suction Cup • For moving large shallow dents that are not creased • Wet surface and suction cup • Attach to the surface & pull on cup • It may be necessary to hammer to release tension • Use a mallet or a body hammer with duct tape on the face to prevent damage to the paint

  8. Using a Body Hammer – Holding The Hammer • Hold hammer tightly to prevent slipping • Extend index finger over the handle to help guide blows • Hold sides tightly to prevent sideways movement

  9. Using a Body Hammer – Hammering Techniques • Strike strongly for initial straightening • Swing using wrist when finishing • Hammer face should be flush with metal, otherwise a sideways blow will damage metal • Use light, consistent blows • Metal stretches when hammered

  10. Using a Dolly Block – Holding The Dolly Block • Top Surfaces • Place in palm • Hold lightly placing curved surface toward panel • Using corner • Hold lengthwise • Place corner on contour of panel • Using Edge • Place edge against body line or sharp contour

  11. Using a Dolly Block – Holding The Dolly Block • Using the dolly to raise large surfaces • Can be used to strike panel • Moves large areas of metal

  12. Hammer and Dolly Block – Variables • Force of the hammer blow • Force of the dolly rebound • Shape of the face of the dolly • Hammer-on-dolly – Dolly directly behind where you are hammering • Hammer-off-dolly – Dolly off to one side of where you are hammering

  13. Hammer-On-Dolly • Also called dinging on dolly • Both dolly and hammer must have same contour as panel • Smoothes metal and allow hammer to rebound • Causes metal to stretch • Most effective for shallow dents • Continuously move dolly under metal

  14. Hammer-Off-Dolly • Also called dinging off dolly • Place dolly under dent and hammer around edges • Hammer highest dent first • Never hammer on low area when using hammer-off-dolly • Work from outside of the damage to the middle

  15. Using Hammers and Dollies to Remove Minor Damage • Use dolly to raise low areas • Monitor low spots • Use hammer-on & off-dolly to return metal to contour • Use pick hammer to lower high spots • Panel must be within 1/8” to use plastic filler • Use disk grinder to prepare panel for filler • Don’t overheat metal when grinding

  16. Removing Damage With Spoons • Also called spring hammering • Similar to dollies • Allows use in hard-to-reach areas • Spreads hammer force over a larger area • For prying out damage by levering • For driving out damage by striking end with hammer

  17. Removing Damage With Picks and Pry Bars • For pushing from back of panel • For areas where dollies and spoons cannot reach • Access through holes in inner panel • Do not damage the access holes when prying • Don’t drill access holes unless necessary

  18. Removing Damage With Picks and Pry Bars – Uses • Locate high & low areas • Apply pressure to locate pick location • Do not exert too much pressure in any one area • Use hammer to relieve tension • Work around area until flat

  19. Using Slide Hammers • Many attachments • Can be used to straighten panel flanges

  20. Using Slide Hammers – Screw Attachment • Drill 1/8” hole in low area • Screw in and use force of weight to move metal • Metal can easily be stretched or torn • Use hammer and dolly to finish repair • Weld all holes closed

  21. Using Slide Hammers – Welded Studs or Washers • Weld studs or washers in low areas • Use force of weight to move metal • Do not stretch metal • Use hammer and dolly to finish repair • Use side cutters & angle grinder to remove studs

  22. Welded Stud Safety • Make sure electrical cord is in good order • Do not work on wet surfaces • Do not burn through panel

  23. Removing Damage With Pull Rods • Similar to slide hammers • More than one rod may be needed to remove damage

  24. Removing Damage With Pull Rods – Uses • Drill 1/8” hole in low area (don’t drill into intrusion beams or reinforcements) • Insert rod in hole and pull • Use body hammer to release tension • Do not stretch metal • Use hammer and dolly to finish repair • Weld all holes closed

  25. Removing Severe Damage – Technique • Straighten edges and body lines first • Return metal to original contour with hammer & dolly • May have to use welded studs, slide hammers, or port-a-power

  26. Removing Severe Damage – Use of Hydraulic Jacks • For moving large areas of metal • For panels with light to moderate damage • Used when panel can be straightened be pulling or pushing • Avoid damaging adjacent panels • Do not stand directly in the line of pressure or force • Make sure the ram & attachments are properly secured

  27. Removing Severe Damage – Use of Metal Tabs • Welded to damaged areas for pulling or pushing • Use hydraulic jack for pulling or pushing damage • Use hammer, dolly, or spoon to work area to proper contour

  28. That Concludes Module 1D2