How 2 hammer out your fenders - save the A-line, save the fender

[DMZ73]

Hey,
I thought i might take the time to share my knowlege of sheetmetal work. Many times we can not pruchase a new part. For those of us who can't afford a new part, sometimes there is a way to save what you have. In my case, I have rust free-fenders, that were a little dented. Scratch that, one was mangled. Many times people would rather cut out and replace sections, but I find it rather rewarding to get close to what you had, considering you often need to featherfill anyway. In this post, I will detail how to get from A to Z, with illustations and images, for all that want to know how to work some metal.
I learned it from my grandfather many years ago. I still use his tools, and as much knowlege as I could retain. I also took a metals class in college- Hand-forming, mind-you.

So, here is what it looks like when I started.
< http://www.pbase.com/dmz73/image/72518698 >

And here is where I am at right now.
< http://www.pbase.com/dmz73/image/72463991 >

The following replies I will include a step by step.

Dan

[moparclown]

Wow nice to see that kinda work,very impressive.I love to smash metal back into shape.I am still learning so keep posting and I am in the same boat as you,money is tight so if I can I fix it,Then thats what its got to be.

[TreeFrog]

yes, mine buckled out at the wheel well opening.  so the natural curve from top to bottom is all but flat on the pass side. Looking forward to the posts.

[GoodysGotaCuda]

nice work. care to give this a shot (its more jacked up than it looks). 

[JimCuda]

Nice

[DMZ73]

Goody,

Its fixable. Most panels are. Especially siince they are hard to find, and not yet available as a new part.

The key to fixing damaged panels- try to pull them out the same way they went in.

You can make a wooden Jig to help pull the part out the same way it went in. It's not easy, but it is possible. Once you make the Jig you can attatch it to a car or an immovable object and slowly crank the part back into position.

Dan

[jeryst]

Great thread. I love when people pass on knowledge. Since you are a body guy, I have a question. Many times, I have heard body guys referring to "stretching" and "shrinking" metal. What does that mean, when does it occur, and how do you fix it?

[DMZ73]

Correct me if I'm wrong here.

Stretching - Heating and hammering hot. This is something I have done only forging solid pieces.

Shrinking - Heating and Rapidly cooling, hammering cold. Something I have yet to try on a panel. I heard it works well. Just have to get up the nerve.
I try to get things as close as possible without going out of the target zone - 1/8th" to 1/4" from  highlighted surface.
I use body hammers, dollys and hardwood.
A previous owner had used the ol slidehammer on the panels, and seemed to do it in the correct direction. So I went with it.

Dan

[JimCuda]

Stretching - Heating and hammering hot. This is something I have done only forging solid pieces.

Shrinking - Heating and Rapidly cooling, hammering cold. Something I have yet to try on a panel. I heard it works well. Just have to get up the nerve.

I have seen people do this, you can get good results with heat, however keep in mind that when you heat up this type of metal and hammer on it, you will make it weaker. However much like you stated, seeing that these panels are not easy to come by and are not cheap.

Goody, you can't hurt anything by trying to pull out the dent, drilling it (then add metal back), hammering it, or heating it. Use what ever means to make it look usuable again. If you can't get it completely flat or straight a little filler never hurts. If you don't have the tools or time, take the fender to a shop that can make it straight again.

Just remember, something is better than nothing.

Just my 2 

[GoodysGotaCuda]

Thanks guys, that does make sense on the pulling it the way it went in. Looks like the body shop found a fender (insurance is paying for it) i dont have to worry about it. Now i just have a scrap fender too 

[RUSTY Cuda]

If you can get a hold of a stud welder, you don't have to drill any holes in the metal to pull dents, I used it a little on mine, but watched a metal guy work miracles with that, a hammer & a couple a dollies! Rich.

[TreeFrog]

The Stud welders are pretty cool.

[dougs bs23]

Thanks guys, that does make sense on the pulling it the way it went in. Looks like the body shop found a fender (insurance is paying for it) i dont have to worry about it. Now i just have a scrap fender too  quote]

Thats not a scrap fender you have there,,, As i see it,, you either have a usable/repairable fender you can resell to someone who needs one,,, or  Another piece of art for your mopar room wall

[Kapteenikosmos]

I would greatly appreciate hammering techniques. My ps side door has a gotten a pretty big punch at the center of the door. Last weekend I gave it some slidehammering and got most of the sharp dent back up but it seems that about half of the door skin has gone in almost an inch.
I'm going to remove the door skin from the frame and hammer it back to the shape. Can't hammer it while it's on the frame because of the side crash beam (or whatever it is called)

So, keep the pics coming up! 

[RUSTY Cuda]

Thats where the studs come in, studs in the low areas, hammer very gently on the highs all around it as you keep tension on the stud, on bigger areas you will repeat this lots & lots, work alittle at a time you will be surprised how close you can get it with patience! Rich.