Automotive Bodywork and Rust Repair
Page 33
gleaned from watching this repair
school texts on autobody work in
There are a few publicly known
process that the highly skilled crafts-
general, and on sheetmetal work in
and legendary practitioners of the
man who was performing it suc-
particular, are quite useful. One trea-
metal forming arts. Fay Butler and
ceeded so well because he worked
sure trove of this kind of information
Ron Fournier come to mind. When
with the metal and not against it. He
is texts on aviation sheetmetal work.
you see anything having to do with
used minimal force and maximum
The requirements for forming and
these individuals, and a few others
planning and manual skill. He never
jointure in aviation are more difficult
like them, grab it. It can be books,
fought the metal, or became frus-
to achieve than they are with auto-
articles, pamphlets, video tapes,
trated with it. Instead, he used its
motive sheetmetal; so, logically,
DVDs, seminars, and so forth. Expo-
characteristics and nature to per-
many of the advances in this craft
sure to greatness is never wasted, par-
suade it to work with him. I have
have come from aviation. Several avi-
ticularly when you are trying to
never forgotten that experience. At
ation manuals, particularly military
learn something important.
an early and impressionable age, it
aviation publications, offer great
In the end, it is your own talent,
instilled in me a love for great metal
insight into the very best techniques,
natural curiosity, and dedication that
work and for finding the best solu-
tools, and equipment for performing
will make it possible for you to learn,
tions to metal working problems.
metal work.
and continue to learn, the metal-
I also have had the privilege of
Beyond books and periodicals,
forming craft. Outside information
seeing that level of skill and dedica-
there are the experienced practition-
and guidance will aid your quest, but
tion lavished on automotive sheet-
ers of the sheetmetal crafts. You can
it is how you integrate that knowl-
metal
repair,
restoration,
and
seek to benefit from their insight in
edge with what you already know,
fabrication projects. It is a beautiful
many ways. You can try to spend
and how you learn to implement it,
thing to behold. Sadly, there have
time watching workers in shops per-
that will count most in the end.
been times when I have seen its
forming this work. Of course, most
If, every time that you perform a
opposite: crude, ugly work, per-
shops don’t cater to hangers-on, par-
sheetmetal task, you ask if there is a
formed with excessive violence and
ticularly the best high-end shops.
way to possibly improve how you are
minimal thought, with results to
Your best bet in this regard is to
doing it, you are on the right track. If
match. The contrast between these
approach a shop with some very spe-
you expend the thought and effort
two extremes of metal work caused
cific issues and questions that you
to try to find that better way,
me, early in life, to seek to know the
would like to have them help you
whether you actually ever discover it
best ways to work with sheetmetal. I
work out. It’s worth a try.
or not, your work will improve just
quickly discovered that the best
Experienced individuals can also
from your enhanced engagement
place to start learning about this
be located and engaged in discussion
with it. Ultimately, your skills and
craft was to watch its best practition-
via sites and forums on the Internet.
imagination will always impose the
ers at work, and then to mimic and
My good friend, Terry Cowan,
most implacable limits on what you
experiment on my own.
started the Metal Shapers Association
can accomplish, but most people
Another way to start learning
many years ago, back when the
never get anywhere near those lim-
about the sheetmetal craft is to read
Internet was young. He did it
its. Sheetmetal work is a great place
about it in books like this. There are
because he had a lifelong passion for
to try to attain them.
AUTOMOTIVE BODY WOR K AN D R UST R E PAI R
159
APPENDIX
Soldering Data
The steel thickness chart graphic
indicates the transition tempera-
tures between the three states, or
“phases,” of tin/lead solder alloys—
solid, past, and liquid—over a range
of temperatures. Note that the
“eutectic” mixture of tin and lead is
63/37. That means that the alloy of
these metals with the lowest possible
melting point (361 degrees F) is 63
percent tin and 37 percent lead, by
weight. This is usually expressed as
63/37.
Note also that 20/80 solder alloys
show the broadest temperature range
of their pasty state, from 361 degrees
F to about 530. This is important
because that is the range in which
they can be worked with a paddle. A
30/70 solder alloy enjoys workability
from 361 degrees F to about 490, still
a comfortably wide temperature
range. Beyond that, there is no par-
ticular reason to increase the tin con-
tent of body solder.
Colors of Steel at Different
Temperatures
Degrees F. High Temperature Colors
Degrees F. High Temperature Colors
This chart indicates the colors of
steel associated with increasing tem-
752
Red, Visible in Dark
1832
Bright Cherry-Red
peratures. It is a useful guide to what
885
Red, Visible in Twilight
2012
Orange-Red
to expect when you heat mild steel.
975
Red, Visible in Daylight
2192
Orange-Yellow
Note that annealing takes place
1077
Red, Visible in Sunlight
2372
Yellow-White
between 700 and 800 degrees F,
1292
Dark Red
2552
White Welding Heat
roughly, the point at which you
would just begin to see red col-
1472
Dull Cherry-Red
2732
Brill
iant White
oration in steel in a dark room.
1652
Cherry-Red
2912
Dazzling White (Bluish)
160
AUTOMOTIVE BODY WOR K AN D R UST R E PAI R
Document Outline
Contents
Acknowledgments
Introduction
Chapter 1: What You Should Know Before You Start Panel Types, Configurations and Reinforcements
Autobody Steel
Plasticity and Elasticity
Work Hardening: The Metal Remembers
At the Factory and Afterward
Necessary Tools and Equipment
General Considerations
Chapter 2: Limits of Materials, Equipment and Skills Inherent Advantages
Divide and Conquer
Chapter 3: Types of Jobs Damage Repair
Small Rust Repairs
Small Patch Price Welding Methods
Chapter 4: Cleaning, Modeling and Cutting Preparing and Cleaning Sheetmetal
Cutting Panel Materials
Getting Shapes and Contours Right
Chapter 5: Forming, Fitting and Smoothing Simple Tools and Equipment
Applying Plasticity/Elasticity, Work Hardening and Annealing
Hammering Techniques that Work
Bending, Beading and Prying
Power Forming
Pulling Approaches to Moving Metal
Smoothing, Stretching, Shrinking and Forming Operations
Chapter 6: Bumping to Move the Metal the Right Way
Chapter 7: Metal Finishing Indicating, Feeling and Other Human Tools to Determine Panel Surfaces
Filing Done Right
The Art of Pick Hammering
The Disc Sanding Alternative
Chapter 8: Welding Body Metal Types of Joints
Welding Smaller Pieces into Large Constructions
Fixturing
Electric Welding
Chapter 9: Filling The Secrets of Lead Work
The Project: Decklid Panel Repair
Applying Lead Filler Material
Applying Plastic Fillers
Chapter 10: Special Projects and Procedures The Project: Fabricating a Splash Shield
Making Panels and Trim Fit
Quarter-Panel Replacement
Door Re-Skinning
Hanging Doors
Mounting and Adjusting Trim
Chapter 11: Before You Paint The Danger from Behind
Chapter 12: Minor Rust Repair to a Fender Edge The Approach
The First Step: Evaluation
Removing the Bad Metal
Planning and Modeling the Repair
Cutting and Forming the Metal Patches
Final Fitting
Welding Considerations
Cleaning, Positioning, Fixturing and Welding
Grinding the Weld Beads and Shrinking the Bulged Area
Final Steps before Filling
Tinning
Applying the Lead Filler
Shaping the Lead and Finishing the Job
Chapter 13: Repairing Collision Damage in a Decklid The Approach
The Early Steps
Metal Finishing
Filling
Chapter 14: Sources and Resources Local Sources
Non-Local Sources
Knowledge and Problem-Solving Resources
Appendix Soldering Data
Colors of Steel at Different Temperatures