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Aluminum Alloy Body Repair - Overview
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Aluminum alloy body repairs are basically done in a similar manner as for a steel body. However there are some points that are different from each other due to aluminum’s characteristics. In particular, repair tools for aluminum-alloyed bodies are completely different, and must be isolated from, those for steel panel bodies.
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Pulling and Correction Repair:
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Because some aluminum parts cannot be reformed due to their high rigidity, refer to the model specific body repair manual to identify those parts.
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For welding methods, refer to aluminum alloy body welding section. | |
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Be sure to check for cracks after welding. | |
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Never use sanding tools that have been used for steel panels. If tools used for steel panels are used for aluminum alloy panel repairs, iron powder will remain on the aluminum panel, contaminating the welding area. | |
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Always use only stainless steel wire brushes. | |
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When a sanding tools such as a disc sander is used, set their rotational speed lower than for a steel panels. Do not press the sander as hard against the aluminum panel. The heat of friction caused by excessive pressure cause the aluminum alloy surface to peel, clogging the sanding disc surface. It will also deeply scratch the aluminum surface. | |
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Do not use a shrinking hammer. | |
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Do not repair using solder. | |
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Heated aluminum does not change color like steel sheet. Always use heat detection crayon or paint to measure and control the heat input during repairs. | |
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Parts Installation:
Be sure to use fasteners specific deigned with anti-corrosion treatment for attaching aluminum parts.
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Beware of possible thermite reactions while working. Refer to the fire and explosion risks under safety and cleanliness section. | 
