DIY Network

Minor Dent Repair A small dent is pulled out of a car body. From "Trade School" episode DTRS-309

Having conquered the basics of this trade, apprentice James Ackerman hones in on his skills in the finer points of auto collision repair under the wing of repair expert, Mike Rohleder.

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	Dented car before repair...
	...and after.

Materials:

pneumatic tools
air grinder
stud welder
slide hammer
body hammer
disc grinder
body filler and spreader
DA sander
sanding block
refrigerant containment unit
frame rack system
air hammer
tram gauge
clamps
spot welder
MIG welder

Apprentice James Ackerman restores a dent on a fender back to its original contour.

1. Before tackling the dent itself, James must remove the bumper, and then strip the adjacent door panel and hood of accessories to avoid having to mask over them for subsequent paint blending. He takes careful inventory of these accessories as he removes and inspects each for hidden damage (figure A).

2. With all the accessories removed, James starts on the dent. He begins by stripping off the existing layers of paint in and around the dent with an air grinder (figure B).

Figure A

Figure B

3. Now with the metal exposed, James uses a stud gun to spot weld brass studs directly to the low spots in the dent (figure C). He uses a slide hammer to grasp each stud and to pull the metal outwards (figure D).

Figure C

Figure D

4. With the main low spots taken care of, James clips off the brass studs, and then uses a body hammer to tap down any high spots in the damaged area (figure E).

5. With the surface returned to a relatively flush contour, James prepares to apply body filler, which fills in tiny low spots. He first sprays on a coat of anti-corrosive, self-etching primer that also serves to maximize the adhesion of the body filler (figure F). He masks off the engine and wheel well (figure G).

Figure E

Figure F

Figure G

6. James mixes the body filler with a hardening agent, and then spreads it over the dent (figure H). After allowing time to dry, he removes much of the excess with a dual action sander (figure I). James notes that a low spot remains and applies another layer of filler. He then sands the dried filler with a hand block to shape the area along the contour (figure J).

Figure H

Figure I

Figure J

Figure K

7. Having restored the panel to its original shape, James now places the automobile into the capable hands of paint technicians who mask, prime, and paint the fender (figure K).

8. After the new paint has set, James and Mike examine the fender in daylight, which will reveal even the smallest paint and body blemishes if they exist. The repair passes the test, and then James finishes this project by reinstalling the bumper, and accessories. The car is now ready for the customer to pickup.

In the next segment, James continues his collision course by tackling a severely damaged front-end.

RESOURCES :

ABRA Auto Body and Glass
Website: www.abraauto.com