The reality of aluminum body panels.

[JDgreen227]

The repairs are going to be different than steel. With Aluminum you're not going to just pound out a dent. What this means is small dents could cost more to repair than on steel. Larger dents that require the panel to be replaced probably will not cost much different. I personally believe that Ford is eating the extra cost of the aluminum panels to keep costs as comparable to steel as possible. Things that are going to cost a lot more will be structural panels. Things like the support for the fenders, door pillars, etc. They would just be pulled straight if made from steel. With Aluminum they will need to be replaced which will require a lot of work to remove everything attached to and around the panel to be removed. Don't forget the whole panel will most likely need to be replaced. Rolling an aluminum cabbed truck on it's side could mean the whole cab needs to be replaced. I would say the jury is out for at least a year or so. By then insurers will know the real cost of aluminum on a large scale.

Excellent post and well thought out...!!!! :thumbsup: And BTW as I have been following this thread I have wondered: Are the materials needed to fill dents on aluminum body panels any different from those required on steel body panels?

 

[ray66v]

Are the materials needed to fill dents on aluminum body panels any different from those required on steel body panels?

No, they have specific fillers for aluminum. But, if you are already using premium body filler, it is compatible.

The sandpaper is compatible.

And, the paint isn't any different.

 

[crazyal]

No, they have specific fillers for aluminum. But, if you are already using premium body filler, it is compatible.

The sandpaper is compatible.

And, the paint isn't any different.

I think the issue would be removing as much of the dent as possible before using filler. With steel it's pretty easy but will it be as easy with aluminum? For example if your "wife" cuts it a little too close to the mail box and puts a nice crease about a foot long and an inch deep into your door would you want it the metal to be straightened first and then a thin coat of filler or just have the whole thing filled in? How would that type of dent be removed on an aluminum door? Will the people like "The Dent Doctor" be out of business because small little dings can't be removed?

 

[ray66v]

I think the issue would be removing as much of the dent as possible before using filler. With steel it's pretty easy but will it be as easy with aluminum? For example if your "wife" cuts it a little too close to the mail box and puts a nice crease about a foot long and an inch deep into your door would you want it the metal to be straightened first and then a thin coat of filler or just have the whole thing filled in? How would that type of dent be removed on an aluminum door? Will the people like "The Dent Doctor" be out of business because small little dings can't be removed?

Removing the paint is no longer necessary, just dulling it completely with some sort of abrasive.

The paint manufacturers were actually suggesting an etch, and epoxy primer, on bare steel, before the filler. Saying it increased corrosion protection. Which was stupid. Because, once you sand it, you remove the primer around the edges. And, you can't prime before each coat of filler. Lol.

I have things I fixed more than 20+ years ago here, no primer under the filler, and no signs of corrosion yet. Will keep you posted.

You are supposed to remove the temper from the aluminum, before you straighten it. This is done by heating it. It gets softer, and is easier to work then.

Before you fill it, you reheat it, and that is supposed to magically re-temper the metal.

Yeah, a lot of guys are going to be packing in the filler on these, because they are not going to be able to do much with them.

Since aluminum stretches easily, shrinking the panel by heating, and cooling rapidly, with a wet rag, which is a long lost art, may be making a come back. Not sure how it would work on aluminum. It may get too brittle.

I was sometimes able to save steel panels, that were otherwise not repairable, because I learned how to shrink them, when I was a young.

All the dent pullers that use welded pins, and or other devices will be useless. So, it's going to be back to drilling holes to pull out the panel, if you can't get to the back side, which is not something that works out well, if you don't know the right, and wrong way to do it. Maybe they will use a glue on system?

 

[MossRoad]

I think the issue would be removing as much of the dent as possible before using filler. With steel it's pretty easy but will it be as easy with aluminum? For example if your "wife" cuts it a little too close to the mail box and puts a nice crease about a foot long and an inch deep into your door would you want it the metal to be straightened first and then a thin coat of filler or just have the whole thing filled in? How would that type of dent be removed on an aluminum door? Will the people like "The Dent Doctor" be out of business because small little dings can't be removed?

Good question. I wonder if paintless dent removal after hail storms will work on aluminum as it does on steel.

 

[Diamondpilot]

Good question. I wonder if paintless dent removal after hail storms will work on aluminum as it does on steel.

Probably won't be needed with aluminum. It's amazing the abuse the aluminum will take.

As for pulling dents. You will still weld on studs. You will just use a stud welder designed for aluminum.

Chris

 

[ray66v]

Probably won't be needed with aluminum. It's amazing the abuse the aluminum will take.

As for pulling dents. You will still weld on studs. You will just use a stud welder designed for aluminum.

Chris

They may be more resistant, but I can say from experience, they are not immune from hail damage.

As far as PDR goes, I have seen a video demonstration where a hail dent was removed from an aluminum hood, with just a propane torch.

Not sure how traditional studs made from aluminum, will be strong enough for dent pulling.

 

[MossRoad]

Doesn't the torch affect the paint?

 

[ray66v]

Good question. I wonder if paintless dent removal after hail storms will work on aluminum as it does on steel.

I have tried PDR on aluminum, and seen attempts to do so on aircraft, and it is not as easy to do it on aluminum.

But, as I said, I have seen a video, where a hail dent was sucked out of a hood with only a torch.

It has to be the right kind of dent, in the right place.

 

[jix]

Yep............and what about what road salt does to aluminum. Check and old landrover in Canada. Swiss cheese!