straightening mangled aluminum panels - feasible?

I saw a documentary about the "lightweight" E-type Jaguar.
Only 12 were made, so they are worth millions.
Some bloke bought a crashed specimen, and restored it, allegedly
repairing original panels. Now these were aluminum. How can you
straighten it when something is creased over nearly 180 degrees?
I guess you would have to heat it, then bend back about 20 degrees,
then heat again in many steps, until original shape is apparent.
Even then, I reckon he would have needed a lot of bog filler to
getting it looking half decent.

wrote:
> I saw a documentary about the "lightweight" E-type Jaguar.
> Only 12 were made, so they are worth millions.
> Some bloke bought a crashed specimen, and restored it, allegedly
> repairing original panels. Now these were aluminum. How can you
> straighten it when something is creased over nearly 180 degrees?
> I guess you would have to heat it, then bend back about 20 degrees,
> then heat again in many steps, until original shape is apparent.
> Even then, I reckon he would have needed a lot of bog filler to
> getting it looking half decent.

You anneal the panel and wheel it back into shape. Repeat until you have
them all done. Not really all that hard if you know how to work with
aluminum.

--
Steve W.

On 11/27/2015 11:21 PM, wrote:
> I saw a documentary about the "lightweight" E-type Jaguar.
> Only 12 were made, so they are worth millions.
> Some bloke bought a crashed specimen, and restored it, allegedly
> repairing original panels. Now these were aluminum. How can you
> straighten it when something is creased over nearly 180 degrees?
> I guess you would have to heat it, then bend back about 20 degrees,
> then heat again in many steps, until original shape is apparent.
> Even then, I reckon he would have needed a lot of bog filler to
> getting it looking half decent.
>

It's panel beating, no heat. The material is easily
stretched by overwork so it's skilled labor. I've done that
on a smashed MGB bonnet and it is indeed difficult but not
impossible. You're right about the fiberglass/polyester
filler - can't lead fill dents and holes on aluminum.

--
Andrew Muzi
<www.yellowjersey.org/>
Open every day since 1 April, 1971