Basic Methods For Door Panel Maintenance; Reconditioning Of Dents - Chery A113 Maintenance Manual

3． Cracks or breaks: The metal plates may develop fatigue under repeated inner/outer stress
where the stress concentrates and the structure is the weakest, causing cracks and even breaks.
4． Dents or wrinkles: Dents develop because the door panel is subjected to bumping or
pressing, leading to elastic or plastic deformations.
5． Bends or twists: They are mainly caused by too much load the door panel receives in use or
the plastic deformation due to bumps.

4. Basic Methods for Door Panel Maintenance

The basic maintenance methods for the above door panel damage types include dent
reconditioning, flame correction, welding, repairing and mending, wrinkle spreading and so on.

4.1. Reconditioning of Dents

For convex-concave damages in the outside door panels, if they are indirectly caused by
structural pieces or reinforcers, the structural pieces should be corrected first, and then the outside
panel breaks or dents are to be corrected. If the backs of the metal panels are accessible, hand
hammers and underlay irons or spoon-shaped irons, tommy bars, flat punches and so on can be used
for primary repairs. For enclosed metal panels or parts that are difficult to access from the backs,
other tools can be used for repairing, such as slide hammers and pointed hammers.
Here are some common ways of dent reconditioning:
(1) Repair the dents with underlay irons and hand hammers: the commonest practice is to beat
the damaged metal panels with underlay irons and hand hammers. Both sides of the metal panel to
be repaired must be accessible to the hand-held underlay iron and there are two ways of using the
underlay iron as the supporting piece for the hand hammer:
① Beat with a hammer from above the underlay rion. This approach is suitable for correcting
smaller and shallower dent or breaks.
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