That 2015 Ford F-150 aluminum panel fight I had last month

Had a guy bring in his 2015 F-150 with a dented driver side rear door. I figured no big deal, but that aluminum skin fought me every step. Took three tries with the stud welder to get a clean pull without burning through the metal. Anybody got a go-to technique for aluminum body panels that doesn't involve replacing the whole door?

3 comments

3 Comments

sean8542d ago

You try preheating the panel with a heat gun first?

aaron_mitchell2d ago

Wait, you're saying you preheat the aluminum with a heat gun BEFORE you even start pulling? That's actually kind of BONKERS to me. I've always just hit it with heat AFTER the stud is on, but the idea of warming the whole panel up first to make the metal more pliable before pulling... that's honestly genius. Does it help keep the aluminum from cracking or tearing around the weld? Cause that's my biggest headache with these newer cars, the metal just wants to split no matter how gentle I am. I'm gonna have to try that on my next dent, for real.

hugos462d ago

Used to be one of those guys who swore you just treat aluminum like steel with a few more amps. That door skin proved me dead wrong. The heat gun trick works if you're careful not to overdo it and warp the panel around the dent. My go-to now is a lower heat setting on the stud welder and a really slow pull with a slide hammer, not a quick yank. That aluminum tears way easier than you'd expect if you rush it. You tried a glue pull on aluminum yet or just sticking with the studs?