Thread: Panel beating - Can this one be done?

That is an easy repair if you know what you are doing. If no access from in side, then drill a couple of holes, use an l-shaped puller (slide hammer), then weld up the holes (not essential), grind, bog, sand, uc/putty, sand, paint.

It would be a good opportunity to teach yourself how to do panel work.

Originally Posted by Pauly85

a traditional mig welder is no good for aluminium

WTF???

Change the wire to Al, change the tip to the correct size, change to a poly liner and change the gas and you are good to go.

Originally Posted by isuzurover

then weld up the holes (not essential).

WTF??? Since when is it not essential to weld any holes you create in the process of repairing a panel???

Originally Posted by Pauly85

WTF??? Since when is it not essential to weld any holes you create in the process of repairing a panel???

The panel is decorative only, any holes will not affect waterproofing. Ally doesn't bleed rust from little holes like steel does. It's the steel panel inside of that keeps out the dust and water.

Originally Posted by isuzurover

That is an easy repair if you know what you are doing. If no access from in side, then drill a couple of holes, use an l-shaped puller (slide hammer), then weld up the holes (not essential), grind, bog, sand, uc/putty, sand, paint.

It would be a good opportunity to teach yourself how to do panel work.




WTF???

Change the wire to Al, change the tip to the correct size, change to a poly liner and change the gas and you are good to go.

I thought as much being a boiler maker by trade but haven't practiced for 10 years so not being in the game means I've no idea what sort of equipment is now available therefore didn't have the confidence to question the process

Originally Posted by Pauly85

WTF??? Since when is it not essential to weld any holes you create in the process of repairing a panel???

Often the distortion created during welding is more difficult to deal with than a small hole.
I would be apprehensive welding a panel as large and "flat" as a Disco quarter panel. Particularly when access to get a dolly behind is poor.

I've got all of the interior trims out of the back of my Disco at the moment to fit a compressor in the rear quarter.
While it's all apart I noticed this vent in the drivers side quarter inner panel.





It looks as though it may pull through to the inside but there may be screws holding an outer part on.

If you can get it out easily, it should give good access behind the damage on the car you are looking at.

Originally Posted by Pauly85

that is purely cosmetic damage, but the problem with repairing that is its made out of aluminium, so unless it is sent to a workshop that has the proper equiptment to weld a plate to the aluminium panel and pull the damage out, then the only other way to fix it properly is a new quater panel,

from memory there isnt alot of access behind the trims in that area, but having said that it has been a while since ive done a smash repair on a quater panel of a series 2

They can panel beat that. They Panel beat it back into shape and then lead wipe it. That's how Barry Smith Holden at Pennant Hills in Sydney repaired my Discovery's ally panels. You would never know that it has had a hit.

Originally Posted by isuzurover

Change the wire to Al, change the tip to the correct size, change to a poly liner and change the gas and you are good to go.

Its a lot more difficult to MIG ally in comparison to steel and you will burn a lot of contact tips learning. I'd hate to even try it on a thin automotive panel - way better man than me doing that! I'd TIG. You will also need to change the rollers.