I-CAR 2018 Expedition and Navigator Aluminum Body Repair

Introduction

In 2018, I-CAR released a series of courses on the repair of aluminum bodies on the Ford Expedition and Navigator. These courses covered the following topics:

• Identification of aluminum body panels
• Removal and installation of aluminum body panels
• Welding of aluminum body panels
• Painting of aluminum body panels

Identification of Aluminum Body Panels

Aluminum body panels can be identified by their appearance and by their magnetic properties. Aluminum is a non-ferrous metal, which means that it is not attracted to magnets. Therefore, a magnet can be used to distinguish between aluminum and steel body panels.

Aluminum body panels are also typically thinner than steel body panels. This is because aluminum is a stronger material than steel, so it can be used in thinner gauges without sacrificing strength.

Removal and Installation of Aluminum Body Panels

When removing aluminum body panels, it is important to use the proper tools and techniques. Aluminum is a soft metal, so it can be easily damaged if it is not handled carefully.

The following tools are recommended for removing aluminum body panels:

• Plastic pry tools
• Soft-faced hammers
• Heat gun

To remove an aluminum body panel, start by heating the panel with a heat gun. This will help to soften the adhesive that is holding the panel in place.

Once the panel is heated, use the plastic pry tools to carefully pry the panel away from the vehicle. Be sure to use a soft-faced hammer to tap the pry tools if necessary.

To install an aluminum body panel, first clean the mounting surfaces of the panel and the vehicle. Then, apply a bead of adhesive to the mounting surfaces of the panel.

Next, position the panel on the vehicle and press it into place. Use a soft-faced hammer to tap the panel into place if necessary.

Welding of Aluminum Body Panels

Aluminum body panels can be welded using a variety of methods, including MIG welding, TIG welding, and spot welding.

MIG welding is the most common method for welding aluminum body panels. MIG welding uses a consumable wire electrode that is fed into the weld area. The wire electrode is melted by an electric arc, and the molten metal is deposited into the weld joint.

TIG welding is a more precise method for welding aluminum body panels. TIG welding uses a non-consumable tungsten electrode that is not melted during the welding process. The tungsten electrode creates an electric arc that melts the aluminum in the weld joint.

Spot welding is a type of resistance welding that is used to join aluminum body panels. Spot welding uses two electrodes that are pressed against the aluminum panels. The electrodes are heated by an electric current, and the heat causes the aluminum panels to fuse together.

Painting of Aluminum Body Panels

Aluminum body panels must be properly prepared before they can be painted. The preparation process includes cleaning the panels, sanding the panels, and applying a primer to the panels.

Once the panels are prepared, they can be painted using a variety of paint products, including single-stage paints, two-stage paints, and clear coats.

Single-stage paints are the easiest to apply, but they do not provide as much protection as two-stage paints. Two-stage paints provide more protection than single-stage paints, but they are more difficult to apply.

Clear coats are used to protect the paint from the elements. Clear coats can be applied over single-stage paints or two-stage paints.

Conclusion

The repair of aluminum body panels requires specialized knowledge and skills. I-CAR’s 2018 Expedition and Navigator Aluminum Body Repair courses provide the training that technicians need to safely and effectively repair aluminum body panels.