Jeff Lilly
  • Home
  • Shops
    • Mechanical Shop
    • Media Blasting
    • Body Shop
    • Block Sanding
    • Wood Work
    • Paint Shop
    • Upholstery Shop
    • Assembly Shop
  • Gallery
    • Restomods
    • Hot Rods
    • Muscle Cars
    • Pro Touring
    • Trucks
    • Corvettes
    • Classic Cars
    • Frame Off
    • Pre-War
  • Why Us ?
    • Why Choose Us
    • Build Process
    • Beginnings
  • Cost
  • Contact
  • Recognition
    • Endorse
    • media
  • Build Tips
  • Employment

Build Tips

Dent Removal

1
Click to enlarge

A familiar foe. 1954 Ford F100 front fender. The mega dents make it a perfect example to demonstrate all of our favorite techniques. The average person might think that this fender is too rough to use but we know how hard it is to get good sheet metal. This particular fender is rust free for the most part and being that dents are easily repaired by our Metal Meister Mani the decision is clear. Fix-Her. As seen we marked it out for hammer work, slap file and pin dent removal.

2
Click to enlarge

Using a straight edge we determine the depth of each dent to decide on which dolly and hammer to use. Hammer weight and how much the metal needs to be moved along with gauge thickness are very important.

3
Click to enlarge

This one is shallow so a lighter hammer and / or less strike force can be used.

4
Click to enlarge

The back side of the fender where we marked "hammer" is where we will start. A high crown dolly and medium weight hammer will be used. We have the fender flipped upside down for demonstration purposes to show the exact location.

5
Click to enlarge

Using the high crown dolly we place it directly on the highest point to demonstrate. We will now flip the fender back over to perform the techniques.

6
Click to enlarge

Mani holds the dolly as instructed in the last caption. We begin tapping with medium pressure being sure to make square contact with each blow. We perform a circle all around the perimeter on the outer edge of the dent. While holding the dolly on the backside of the center it starts to release the metal allowing it to go back to its original shape.

7
Click to enlarge

Once he gets it roughed out he uses a slapping spoon and repeats the process. This tool allows more surface contact then the hammer but less strike force so it is great for finishing off the smaller imperfections.

8
Click to enlarge

Again working from the outer perimeter in a circle toward the center with the same method the spoon slapper takes it to the next level.

9
Click to enlarge

Once all the dents are worked out he blasts the surface then block sands it with 80 grit for any last spots. He is checking for the right contour and as seen she has a nice shape.

10
Click to enlarge

Using an oval shaped dolly he can work out the little details.

11
Click to enlarge

On to the slapping file. This tool actually pulls the dent out by allowing the metal to release in to the file teeth as it strikes the surface. "Reverse Shrinking" is what the old timers call it. This is a slow but sure method that can be learned with a little time.

12
Click to enlarge

A close up shows the serrated teeth are making contact on the high/level spots and the low untouched areas are needing more attention. The key is to hold the dolly in the low untouched section as you tap it with the file and it will pull the dent out.

13
Click to enlarge

The spot is smaller now so Mani uses a round dome dolly which is excellent for placement in tight areas and small imperfections.

14
Click to enlarge

She is about there and coming around.

15
Click to enlarge

The final step is to DA sand it to check one last time. She is primer ready with no filler needed.

16
Click to enlarge

Another dent removal technique is the stud welder which works great when you do not have access to the back side.

17
Click to enlarge

We find the center and weld a stud on to start the process.

18
Click to enlarge

She is ready for a pull.

19
Click to enlarge

The baby slide hammer makes short work of it.

20
Click to enlarge

Now using the hand tool he taps around the perimeter while pulling 5 lbs of pressure and she starts to work out.

21
Click to enlarge

Once it is the best you can get it simply cut off the pin and grind it flush.

22
Click to enlarge

We also use a long handled dolly for hard to reach areas.

23
Click to enlarge

Placed in the right area he starts to tap it out.

24
Click to enlarge

Slap file again to raise the surface.

25
Click to enlarge

Looking good. Fully touched by the serrated file teeth.

26
Click to enlarge

Sand it smooth to check it.

27
Click to enlarge

Ready to rock.

Jeff Lilly Restorations

11125 FM 1560 N San Antonio, TX 78023

210-695-5151 - FACILITY TOURS BY APPOINTMENT ONLY

Mon- Fri 8:00 - 5:00

The look, feel and sound, you've seen it finished in your minds eye a thousand times. The years go by, as time slips away with the old enemy "procrastination". If it is time to get it done, contact us today to get your machine rolling down the road in style. Please take the time to read the Cost / Faq section by clicking HERE This section will help inform you about the car building process to help you make your best decisions.

Thank You! To contact us with your questions call 210-695-5151 and to send photos or information about your project email us by clicking here.

Follow Us For More

© 2023 Jeff Lilly Restorations