Repair of Minor Body Panel Damage

1. If there is no access to the back side of the body panel to tap out the dent, pull it out using a slide hammer. At the deepest point of the dent, or along its edge, drill or punch small holes at least 2.5 cm (1 in.) apart…


2. …then screw the slide hammer stud into the hole and operate it. Tap with a regular hammer near the edge of the dent to help the metal return to its original shape. When this procedure is complete, the dent surface should be close to its original contour and protrude approximately 0.3 cm (1/8 in.) above the surrounding metal surface.

3. Use coarse sandpaper to remove the paint down to bare metal. This can be done by hand, but the tool shown in the photo will speed up the process. Using finer No. 320 sandpaper, feather the paint for at least 2.5 cm (1 in.) around the dent area.

4. After removing the paint, check by touch rather than by sight whether the metal surface is smooth enough. Tap down high spots and/or pull out low spots as necessary. Clean the repair surface with a wax and silicone remover.

5. Following the instructions on the package, mix the plastic body filler with the hardener. The mixing ratio is critical. If it is not correct, the filler will set too slowly or too quickly (and you will not have time to apply and shape it).

6. Working quickly before the filler sets, use a plastic spreader to apply it firmly to the metal surface, making sure full adhesion to the metal is achieved. Shape the filler so that it approximates the original contour of the area and stands slightly above the surrounding surface.

7. Allow the filler to harden until it can be dented only with a fingernail. Rough-shape the filler with a file or the tool shown in the photo.

8. Using coarse sandpaper wrapped around a block or sanding board, sand the filler until it is smooth and level. Gradually move to finer grades of paper, always using a block, and finish with No. 360 or 400.

9. After sanding, your hand should not feel the transition from filler to bare metal or from bare metal to old paint. When this is achieved, remove the dust and mask the adjacent panels and trim.

10. Apply several coats of primer to the work surface. Do not spray too much primer at once, or it will run. Allow each coat to dry before applying the next. A professional spray gun is normally used for this, but auto parts stores sell primer in inexpensive aerosol cans.

11. Primer will reveal defects or scratches. Fill them with glazing compound. Following the instructions on the package, sand smooth with fine (No. 360 or 400) sandpaper. Repeat the glazing and sanding until the primed surface is completely smooth.

12. Finish sanding with very fine paper (No. 400 or 600) to remove excess primer. Wash the area with water and let it dry. Use a tack cloth to remove all dust, then apply a coat of topcoat. Do not attempt to wipe or apply wax to this area until the paint has fully cured (at least two weeks).