The procedures for replacing a portion of a
damaged panel are as follows:
Determine the amount of damaged area to be
removed. Using oxygas cutting and welding
equipment removes the damaged area.
Once the section of the damaged panel has been
removed. straighten the remaining portion to the
Place a piece of sheet metal over the area that is
cut away. Mark the new sheet metal so that when
you cut on the lines drawn, the piece will be
slightly larger than the area being replaced.
With the new piece of sheet metal held in place
by clamps, weld the sheet metal into place. Work
out to the sides then down the sides. Make a
continuous weld, doing a length about 6 inches
long at a time. To reduce distortion, stagger the
With the new sheet metal welded into place, the
weld should be ground down using a disc sander.
Exercise care while sanding to prevent burning
or cutting holes in the sheet metal.
When replacing sheet metal, it may be necessary to
shrink the sheet metal in order to achieve a
professional fit and finish. Figure 8-67 shows the
procedure for shrinking sheet metal. Only a small area
at a time is heated and shrunk. This will cause the panel
to return to its original contour when performed
PREPARING THE SURFACE FOR
Before actual painting begins, it is essential that
you prepare the surface for the paint by removing all
traces of wax, grease, oil, and dirt. If the paint on the
vehicle is of poor quality or deteriorated, remove it. In
Figure 8-67.Metal shrinking process and sequence used for large areas.