Aluminum Alloy Body Repair - Panel Repair
1. Panel Repair

Hammer off dolly

Hammer on dolly
Correction Using Hammers and Dollies:

Hammering out should be done, basically, the same way as for steel panels.
Because aluminum alloy has a higher elongation rate than steel, select use wood or plastic hammers depending upon the repair requirements.
Always keep the hammer and dolly surfaces polished so they do not damage the panel surfaces.
The hammer off dolly technique is used most it tends to cause less elongation and work hardening. When a hammer on dolly technique is required, pay careful attention to the elongation and tap lightly.
To prevent cracks and deterioration in aluminum parts, do not use solder to repair aluminum alloy panels.





Shrinking (Drawing):

Shrinking of aluminum alloy panels is done the same way as steel panels.
Always use heat detection crayon or paint to measure and control the heat input during repairs.
When using a hammer for finishing, do not use a serrated shrinking hammer or dolly like those used for steel panels because it may cause cracks.





Body Filler (Putty) Repairs:

Proceed with correction and repair the same as for steel panels.
When removing old paint layers on aluminum alloy panels, apply less pressure to the disc sander than for steel panels to prevent distortion.
Use a sanding disk with P80 to P120.
Finish sand filled surfaces with P80 sandpaper.
Featheredge the repair area using P120 sandpaper.
Somebody fillers cannot be directly applied on a raw aluminum alloy surface. In this case, apply epoxy-based primer to the surface before body filler application.
Refer to the specifications issued by the body filler and paint manufacturers for the appropriate body filler or putty to be used on aluminum alloy.