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Kirkham Motorsports University How To Fix An Aluminum Fender
Hey guys,
In keeping with my goal of putting as much information online as possible (special thanks to Kahn Academy), I just finished this video. We had a customer come in with a tire that had delaminated, crunching up his rear quarter panel. Here's how I fixed it. Aluminum is magic :) As always, I am happy to answer any questions. David :):):) |
Simply awesome!
These Kirkham University videos are great. Hard to believe it was the same fender. rodneym |
David,
That's a great service you give to your customers and other tin owners. It's NOT as easy as you make it look. I fear now that Rodknock will empty the kitchen drawer of his tool collection and his Popeil All Purpose jack knife and attempt this at home...:JEKYLHYDE |
Hi David,
I really enjoyed the utube. One question, how much time do you think was involved to fix that quarter? The guys on metal meet will want to know. Thanks Mark. |
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Great video. Thank you! Paul :) |
David,
Thanks for posting the video. Awesome work! On another note: It seems like the rope climbs and gymnasium is treating you well. You are looking younger, slimmer & fitter. Congrats |
I tried to anneal the the rear quarter on my car, it didn't work??? :o
But seriously, when you want to do some hands on classes, I'll be one of the first in line. Thanks for the video!!! :MECOOL: |
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David :):):) |
Awesome work, David. I admire your patience for working the wrinkles out. It taught me something, I usually go for the deep wrinkles first like the area where it folded back. You showed how to go for the overall shape and gradually bring it all into place. Now the big question I have is, how many actual hours did that operation take? 13 minutes of video time equals what actual time? My guess is 4-6 hours.
Love the use of the office chair also! |
Amazing work David...it's a privilege to watch all you guys do!!!
To have CRAFTSMAN such as yourself willing to share the work you do everyday, really gives an appreciation of the Kirkham and Value adds to what is already the benchmark!!! Can't wait for the next Video!!...:cool: |
awesome!!!!!!!!!!!
thanks!!!! |
So David, you're not just another pretty face! Nice job.
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Finally, the damage wasn't confined to the area in the video (I just limited the video to the major damage so the video wouldn't get too long to upload). The trunk gaps were messed up because the fender had been pulled away from the trunk. There was also damage by the jack hooks where the metal tore and had to be welded up. All these things were fixed at the same time and I didn't keep records of exactly how much time the damage in the video took. David :):):) |
David
Does this process make the aluminum anymore brittle? |
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Think about rolling out a plate of aluminum to make sheet. The plate is rolled and rolled and rolled. It is annealed along the way and it doesn't make the aluminum any more brittle. David :):):) |
davd, The hammer and dolly work does not work harden the alloy?
I saw the panelbeaters at Autokraft in 1985 weld the aluminum using "parent metal" (strips of the alloy) and "sooting" the weld area up. When they changed the flame mix they heated until the soot burned off and just after that point the "rod" would flow into the weld area. of course a little more heat and the whole mess ran onto the floor in a puddle....... |
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Hammer and dolly work does indeed harden the aluminum (just like most any metal). The term in the industry for this hardening process is "work hardening." Any time you bend, twist, pound, forge, or otherwise move metal, it hardens. Annealing removes the work hardening and returns the metal to a soft state. You can do it over and over again (hence, my reference to rolling ingot into plates and sheets). Each time you roll the plate, you refine the grain structure (like our wonderful 5083 SPF alloy)--but that is a discussion for another day :) As to the process you describe, it sounds more like aluminum brazing than welding. If there is any soot at all on a panel before you weld the soot will severely contaminate the weld. I have never had any luck brazing (the joints were not ductile at all). Welding aluminum is very similar to welding anything else--you make a puddle and dip the rod into the puddle to make a joint. The rod doesn't ever "flow" into a joint. David :):):) |
It is amazing that you can get the original metal back into shape.
I'm curious though. Would it have been easier and faster to cut out the piece and weld in a new piece of fender? You seem to have a tool for everything. I liked your specialized panel beating chair. :JEKYLHYDE |
I know it doesn't matter, but out of curiosity. What does the back side of the panel look like after this is all done?
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David...best KMU episode yet, and should answer the usual first question folks have about arruminum. ;)
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