Ford F-150 2015 Structural Repair Training Course page 45

Textbook
6XXX￿series￿aluminum￿gets￿its
strength￿from￿heat￿treating.￿This
means￿that￿service￿parts￿will￿be
shipped￿to￿the￿repair￿facility￿at
their￿hardened￿state.￿Depending
on￿the￿specific￿alloy,￿bends￿in￿the
part￿may￿require￿a￿gradual￿radius
bend.
thickness￿of￿the￿panel.￿Although
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the￿type￿of￿alloy￿can￿affect￿the
strength,￿so￿can￿the￿thickness.
The￿thicker￿the￿material,￿the￿more
prone￿it￿is￿to￿cracking.
visibility￿of￿the￿area.￿If￿the￿area
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is￿on￿a￿door￿assembly,￿the￿visual
appearance￿is￿important.
special￿tools￿available￿that￿will
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help￿create￿a￿gradually￿rolled￿hem
flange.
Ford￿is￿offering￿a￿replacement￿door￿skin
as￿a￿service￿part.￿Before￿installing￿the
door￿skin,￿ensure￿that￿the￿door￿frame￿is
straight.
Exterior￿panels￿on￿the￿2015￿Ford￿F-150
are￿made￿from￿6022￿aluminum￿alloy.
Keep￿tools￿for￿working￿with￿aluminum￿separate
from￿tools￿used￿with￿steel￿to￿limit￿the￿possibility￿of
contamination.
2015￿Ford￿F-150￿Structural￿Repair￿Training￿Course￿(FOR06)
Module￿3￿-￿Aluminum￿Joining￿Methods
When￿forming￿the￿flange￿on￿an￿aluminum
part,￿repair￿tools￿that may￿be￿used￿include
a:
hammer￿and￿dolly.
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hem￿removal￿tool.￿There￿are￿some
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specialty￿tool￿vendors￿that￿offer
tools￿that￿will￿open￿a￿hemmed
flange.￿This￿tool￿is￿offered￿by
Rotunda￿and￿part￿numbers￿are
501-078/1￿and￿501-078/2.
hem￿installation￿tool.￿This
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tool￿gradually￿folds￿the￿flange,
decreasing￿the￿possibility￿of
cracking￿the￿rolled￿edge.￿One
option￿that￿is￿offered￿by￿Ford
is￿a￿Rotunda￿tool,￿part￿number
501-080.￿This￿tool￿is￿used￿to￿roll
the￿flange￿of￿the￿door￿skin.
Refer￿to￿the￿Video:￿Rope￿Hem￿Flange￿in
the￿presentation.￿This￿video￿discusses￿how
a￿rope￿hem￿flange￿is￿made.
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