[BipolarBob]

So, when you get a dented fender or tail section, how do you repair it?

[crazycat]

Shhh...yr not supposed to ask such logical questions.

[Jonty30]

ALthough I’m knowledgeable about the whole process, I do know that they use heat and pressure for any dents.

[who_would_fardels_bear]

I accidentally dented the quarter panel of a Mercedes and it cost my insurance company $1000.

Imagine having to replace the entire back end of the car because the person doesn't just want to fill the dent with bondo.

[Reverend Wright]

Fenders and doors etc are close panels, which are bolted on.

These big die castings are going against the basic characteristic of aluminum which is 6-8 percent shrinkage on solidification.

Now that is a volume shrinkage but it is still 1.5-2 percent in every direction.

Well, for a 70 inch wide car, 1.5 percent is an inch of shrinkage. Now they design the foundry tooling and die caster for directional cooling etc. to try to minimize that.

But the shrinkage on solidification of aluminum has always limited the casting sizes, and created a lot of scrap because of casting porosity and core shift.

[catnipman]

sounds like you might have to replace the entire body ...