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Steel Panel Replacement
Cut damaged panels precisely with 3M™ Cubitron™ II File Belts for a unique combination of simplicity and speed.
Keep the grinding area as precise as possible to avoid unwanted damage to thin sheets.
Decreasing sheet thicknesses requires more precise repair methods. The danger of sanding through because of too coarse grain-grinding is rising. Steels panel are difficult to replace - drilling to open the spots becomes a real challenge when dealing with high strength steels.
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Using the innovative 3M™ Cubitron™ II File Belts saves at least one working step against common drilling out methods - cleaning and opening the spots happens in one easy step without running the risk of weakening the material, common in not precise drilling operations.
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As you are only working from the front and on the panel to be removed, the high strength steel structural parts remain virtually untouched - the structural strength of the car body is preserved.
Click the play button in the image to watch the video
Download Steel Panel Replacement Process Brochure (PDF, 608KB)
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Products to remove a damaged steel panel
Discover our range of damaged panel removal products to help achieve high quality, efficient repairs in your bodyshop.
How to remove and replace a damaged steel panel
Step-by-step process guide to remove and replace a damaged car panel
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Step 1 - Replacement panel cutting
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- Identify car manufacturer recommended sectioning location, scribe or mark with tape on the vehicle and replacement panel
- Trim repair area using preferred cut-off wheel
Recommended products:
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Step 2 - Replacement panel preparation
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- Clean and prep remaining mating flanges on replacement panel with a Scotch-Brite™ Belt or Disc where necessary
- Clean and apply weld-thru primer to all areas requiring welding methods for corrosion protection
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Step 3 - Sealer/Coating removal
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- Use Scotch-Brite™ Belt to remove coatings and seam sealers in hard to reach areas and along pinch weld flanges to expose spot weld locations
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Step 4 - Spot weld removal
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- Grind spot weld to remove weld from top panel. Note top panel thickness
- Use caution when grinding to only grind top panel and limit cutting into host/interior panel
- Separate exterior panel from the host panel after additional pre cut
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Step 5 - Final cut
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- Identify final cut line at the overlapping area of the pre cutted host and replacement panel
- Trim repair area using preferred cut-off
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Step 6 - Weld surface preparation
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- Clean and prep remaining mating flanges on replacement panel with a Scotch-Brite™ Belt or Disc where necessary
- Use caution to limit amount of grinding done to adjacent areas in terms of substrate thickness
- Clean surface and apply weld-thru primer to all areas requiring welding methods for corrosion protection
Recommended products:
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Step 7 - Panel Bonding
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- Apply adhesive to mating flange areas on host panel and replacement panel as recommended from car manufacturer by covering all bare metal areas
- Apply an additional bead of adhesive at mating flange areas to ensure proper bond line thickness
Note: A new cartridge needs to be callibrated as recommended before the first application, to allow initial equalisation! Any further material from there is good to use.
Discover our complete panel bonding processRecommended products:
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Step 8 - Welding
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- Using car manufacturer recommended welding methods at the different areas of the car body lines
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Step 9 - Weld cleaning
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- Use 80+ grit to equalize WPS welding spots and MIG brazing joints
- Fine sanding of weld site in preparation for subsequent operations
- Use caution to limit amount of grinding done to adjacent areas in terms of substrate thickness
Recommended products:
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Technical tips for cutting and replacing steel car panels
Here are some valuable insights into specific challenges surrounding cutting off damaged panels and replacing them, including quick tips on preventing common issues such as....
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Removing spot welds from high strength steel
Customer Challenge:
OEMs are using high-strength steel, making it more difficult and time-consuming to remove spot welds during panel replacement. What’s the best solution?
Technical Tip:
File belts are a fast and efficient way to remove spot welds, even on challenging substrates. Using file belts vs. drilling or spot weld cutting tends to provide technicians a more efficient, controlled method with less fatigue, while helping reduce damage to host panels. The narrow profile of the file belt also makes it much easier to remove hard-to-reach spot welds. 3M recommends using 3M™ Cubitron™ II File Belts , available in 36+, 60+ and 80+ grades. 3M also offers 3M™ File Belt Sanders for Body Repair. -
Equalize WPS welding spots and MIG brazing joints
Customer Challenge:
Special steels from OEM´s are sensitive to thermal stress and heat entreapment. This can leads to the danger of sanding through and to generate too large rpair areas.
Technical Tip:
Use caution to limit amount of grinding done to adjacent areas in terms of actual OEM substrate thickness and in preparation for subsequent operations. 3M recommends using 3M™ Cubitron™ II Roloc™ Fibre Disc 786C, 80+ for a fast removal, less heat entreapment and a finer surface finish. 3M also offers 3M™ Pistol Grip Disc Sander for Body Repair. -
Generate a straight and final cut line at the host and replacement panel
Customer Challenge:
Air saw and vibration cutter cannot do a rough cut in a reasonable time, because those common tools are not suitable to separate several layers of modern high-strength and ultra-high-strength steels.
Technical Tip:
Do the final cut line at the overlapping area of the pre cutted host and replacement panel. This method generates the perfect gap size to fill with MIG soldering and will generate the perfect adhesion for the solder to the substrate. 3M recommends using the 3M™ Cubitron™ 3 Cut-Off Wheels available ø 75 mm , ø 100 mm for a prcise and straight cutline. 3M also offers the 3M™ Cut-Off Wheel Tool for Body Repair.
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Join the 3M Collision Repair Webinar Hub and hear first hand from our experts:
- New industry standards, new products and technologies
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- New design solutions for the collision repair industry
Discover more from 3M
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Remember to always select appropriate Personal Protective Equipment - Eyewear, gloves, hearing and respiratory protection for your job and workplace!
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We don't just have solutions for replacing steel panels. See our extensive range of solutions for all your car repair needs!
