Ford Fiesta (2011 year). Manual — part 97

Rod sander

Another option for separating resistance spot welds
is to use the rod sander.

If spot welds and MIG welds are difficult to reach,
a rod sander may offer an alternative.

Short stroke saw

The short stroke saw is suitable for separating
vehicle body components and for making a
separating cut for partial repairs.

NOTE: In order not to damage panels, wiring
harnesses, hoses or similar components which lie
behind, remove them beforehand as necessary.

The narrow design of the saw blade permits cutting
in tight curves. Straight cuts require a relatively
great deal of practice.

Orbital saw

Where use of the short stroke saw is difficult
because of the body construction, the orbital saw
can be used.

The cutting depth of the orbital saw can be set.
This allows separating cuts to be made, despite
panels or other components lying in danger behind.
Straight cut lines can be more easily made using
the orbital saw.

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Panel Beating Technique and Smart Repairs

General

Smaller scale body repairs, where damaged panels
do not need to be replaced, can often be carried
out by realignment work. Whether the repair is
economical however, often depends on the
accessibility of the affected body area.

NOTE: Basic and in-depth training courses are
offered on the topics which follow. An overview of
the complete range of training offered is provided
by the Ford Service Organization Training
brochure.

During damage assessment, the following technical
points must be taken into account:

• Small mild dents (without damage to the paint),

which are in areas that make access from the
inside possible, can be rectified using
undamaged paint panel beating.

• If the inner side of the damaged area (with paint

damage) can be accessed, then conventional
panel beating techniques can be used.

• If the damaged area has no access from inside,

then it can only be rectified using outside panel
beating techniques.

Dent removal using special panel
beating levers

NOTE: In the Undamaged Paint Dent Removal
section, you will find more information on pressure
techniques.

Description

Des

cript

ion

Deflection by a hook arrangement

1

Pressure tool

2

This panel beating technique with pressure is
mainly used to rectify smaller dents as a result of
hail impact, transportation or parking, without the
paint being damaged.

Small dents are removed from the inside of the
body panel by pushing them outwards in a
mechanical process using panel beating levers.

Because of the great variety of shapes of these
levers, it is possible to use this panel beating
technique on almost all areas of the vehicle body.

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Dynamic puller with counter bearing

Description

Des

cript

ion

Puller device for minor damage, with
integral copper electrode

1

Puller device for more extensive damage

2

U-washers spot-welded in place

3

Puller bits spot-welded in place

4

Attachment for U-washers or puller bits

5

This method can be used to reshape dents or more
extensive damage from the outside.

For minor damage, the copper electrode in the tool
is secured onto the panel surface by spot-welding
and the puller device is used to pull out the damage
without jolting.

For more extensive damage, puller bits or
U-washers (depending on the application area) are
spot-welded to the panel surface and the area
pulled out using the puller device.

Because of the versatile puller and the variable
counter bearing, a wide variety of damage can be
worked and rectified using this repair method.

Because of the mechanical lever operation, the
variable counter bearing and the optimum
controlled application of power, this external dent
removal system allows dents in almost all vehicle
body areas to be pulled out.

Hollow leveling (removing dent without
a dolly)

Hollow leveling can only be used on areas which
are accessible from the rear.

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Description

Des

cript

ion

Center of dent

1

Spoon

2

During hollow leveling, the dent is removed from
the inside a using suitable panel beating tool and
applying knocking or pressing movements. High
spots around the edge of the dent area are
flattened with blows from the aluminum or wooden
headed hammer.

The usual tools are for instance hammers of
various designs, dollies, levering irons and various
spoon irons. The correct choice of tool is made
depending on the shape of the dent and the access
which is possible.

Dent removal using hammer and dolly

Panel beating can only be performed using a
hammer and dolly if access can be gained from
the rear side.

Description

Des

cript

ion

Aluminum hammer

1

Box file

2

The purpose of the dolly in this case is to transfer
the force of the impacts from the hammer to the
steel panel which is in between. As this is done,
the deformed body panel is smoothed (dressed)
and the tension fields in the body panel are
removed.

The favored tool for this repair process is the
aluminum hammer and as opposite support the
universal hand dolly. To rectify minor panel

damage, the box file should be used as opposite
support. Because of its serrated surface, the box
file prevents normal stretching of the body panel
which would otherwise occur.

Heat-induced material shrinking

Material shrinking, also called settling in, can be
performed in a variety of ways depending on the
extent of the damage and the access to the repair
area.

These repair processes differ depending on the
type of heating and subsequent working of the
heated surface. They sub-divide into two basic
processes:

• Heating using a carbon electrode.

• Heating using the oxy-acetylene torch.

In the carbon electrode process the working is done
exclusively by warming. In this case the access to
the repair position is only from the outside.

Description

Des

cript

ion

Carbon electrode

1

Spiral shaped heating pattern

2

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