| Auto Body Repair -- Prepping Damaged Areas |
From "Weekend Mechanic"
episode WKM-109 |
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In this episode, Weekend Mechanic Bruce Bonebrake undertakes some minor body repair on a vintage Alfa Romeo. The repair includes prepping surfaces and sanding away rust, welding, pulling out dents, cosmetically repairing damaged areas with filler, priming and re-painting.
The problem: Our project car, a 1984 Alfa Romeo, has a couple of damaged area in the driver-side door and adjacent quarter-panels. There are dents and some small gashes that extend well below the metal surface, and some rust has set in around the damaged areas (figure A). The cost of repairing this type of damage at a body shop could cost around $1500.
DIY Difficulty Rating for Repair: This type of automotive repair requires some special tools and skills, so we gave it a difficulty rating of 4 on a 5-point intermediate-level scale. Because there are so many steps in this process, this project will require at least a full weekend. More time may be required for more extensive body damage or deterioration.
Important: Included below are the steps in this automotive procedure as shown in the episode. These steps are general guidelines that are applicable to most vehicles. With any particular vehicle, there may be procedures, specifications, settings, tolerances, components, etc. that are specific to that vehicle. Always consult your vehicle's service manual when undertaking significant automotive repairs.
In addition to standard auto-mechanic's tools, some of the pecialty tools required for body work may include:
Disc grinder with wire-brush attachment
Body hammer and dolly
MIG and stud welders
HV-LP paint sprayer
Dual-action sander and sanding supplies
Plastic and fiberglass body filler
Safety equipment required includes:
Welder's helmet and gloves
Respirator
Disposable face-masks
Prepping for Body Repair
Safety Alert: Always wear eye protection -- goggles or safety glasses -- when using any power tools.
- Since the damage is in and around the driver-side door, begin the project by removing the door from the vehicle. First, unfasten and remove the door panel and any trim (figure B). This will make work on the door easier once it has been removed from the vehicle. You may be able to remove the parts using just a screwdriver, but you may also need a panel tool.
- Disconnect any electrical wires running from the door to the body of the car (figure C).
- With the wires disconnected, remove the pins and/or bolts that secure the door to the vehicle (figure D).
- Once unbolted or unfastened, carefully lift the door off of the vehicle (figure E).
- To make work easier, we placed the door on a padded stand (figure F). The padding protects the surface of the door during the repair. Since some of the repair will take place inside the door, we also rolled the window-glass up to avoid damaging the glass during the procedure.
- The damage on the door itself is inspected closely, revealing that the damage extends all the way through the sheet metal (figure G).
- The first step is to manually bend the damaged areas back into place as much as possible in an attempt to close up the gaps. The tools used for this part of the procedure will differ depending on the nature and extent of the damage. In our case, the necessary work could be done using a pry-bar and a large metal-punch and hammer (figure H). Use whatever tools are necessary to bring the damaged areas together as much as possible.
- Using a body-hammer and dolly, we were able to continue working to close the gashes in the door fairly effectively (figure I).
- Next, a small disc-grinder to remove rust and paint from around the damaged area (figure J).
- After preliminary work with the grinder, a wire-brush attachment was used on the grinder to continue clearing away the surface (figure K). The wire-brush attachment is especially useful for cleaning into small cracks and crevices. A sandpaper disc (80-grit) may also be useful
- Because the grinding area extended out slightly beyond the damaged spot, tape was used to mask off the body side-molding and trim (figure L).
In the segment that follows, the cracks are welded shut.
RESOURCES :
The Complete Idiot's Guide to Trouble-Free Car Care
Author: Dan Ramsey
ISBN: 0028635833
Alpha Books
Auto Repair for Dummies
Author: Deanna Sclar
ISBN: 0764550896
Classic Car Restorer's Handbook: Restoration Tips and Techniques for Owners ...
Model: 1557881944
Author: Jim Richardson
Order this book from Amazon.com
H.P. Books
Classic Car Restoration Guide: The Complete Illustrated Step-By-Step Manual
Model: 1850108900
Author: Lindsay Porter
Order this book from Amazon.com
Haynes Publishing
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