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Deep Dent Repair - Repairing Dent in Car
Explore precise repair methods for deep dent repair on state of the art substrates with 3M™ FC Epoxy Metal Filler.
Common methods for deep dent repair can lead to defects and pinholes in modern steel substrates.
Levelling a dent by pulling it often leads to micro pin holes or overstretching of the thin steel. To seal any surface defects, a non-hygroscopic filler should be used to prevent moisture penerating into the metall and causing corrosion.
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Precise grinding tools such as Festool Automotive Systems Geared Eccentric Sander ROTEX in combination with 3M™ Cubitron™ II Abrasives allow less standing steps with a better finish due to finer grids being used.
Using 3M™ FC Epoxy Metall Filler provides you with a non-hygroscopic filler with great adhesion to aluminium, steel and galvanised steel, which is able to seal any micro defects.
Click the play button in the image to watch the video
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Products to repair a deep dent
Discover our range of damaged panel removal products to help achieve high quality, efficient repairs in your bodyshop.
How to remove a deep dent from a car panel
Step-by-step process guide to repair a deep dent in a car body panel
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Step 1 - Pre sanding of the damaged area
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- Perform initial sanding using a handblock in order to spot high and low spots on the repair area
- Perform initial sanding using a handblock in order to spot high and low spots on the repair area. Mark the deepest points in the damaged area in order to place welding points
Tip: Don't remove the paint completely from the damaged area as this will allow you to better complete the dent pulling process and reduce the likelihood of causing holes in the substrate.
Recommended products:
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Step 2 - Surface preparation
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- Remove paint/coating in the low points of the repair area, in preparation for dent pulling
Recommended products:
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Step 3 - Spot application
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- Spot weld onto the repair area using your preferred and recommended method and/or equipment
Note: Always ensure that the equipment properly calibrated depending on the materials being repaired.
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Step 4 - Dent pulling
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- Pull the spots of dent using preferred dent pulling method and equipment
Tip: To avoid surface imperfections or pinholes in the substrate, aim to distribute the load across the repair area.
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Step 5 - Spot removal
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- Spot removal by rotate the welded spot manually
Note: This modern method will reduce the likelihood of causing holes in the substrate and avoid the thin out of the substrate due to a coarse sanding step for the removal.
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Step 6 - Sanding down the job area
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- Sanding down the job area to bare metal
- Switch to ROTEX motion for high abrasion first
- For fine sanding step switch to ROTEX orbital random motion, without changing the sanding disc or grit
Recommended products:
3M™ Hookit™ Cubitron™ II 80+ - 120+, 125mm
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Step 7 - Cleaning of the surface
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- Degrease the surface
Recommended products:
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Step 8 - Application
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- Apply enough 3M™ FC Epoxy Metal Filler for dent filling
- Recomended settings for applicators: pneumatic max. inlet pressure 5.5 bar / battery driven 3kN, max speed 180mm/min
Note: A new cartridge needs to be equalised before the first application to ensure thorough mixing of the product. After the first use, no futher equalisation is necessary.
Recommended products:
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Step 9 - Drying
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- The curing of 3M™ FC Epoxy Metal Filler can be accelerated using IR drying after the initial gelling period. Wait 10 minutes before using an IR dryer to heat for 10-20 minutes with a panel temperature of 70°C
- Airdying: sandable ~ 4 h @ 22°C ambient temperatures
Tip for use: warming up the material & surface to ~30°C before material application will help to accelerate curing, particularly at cold ambient temperatures.
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Step 10 - Sanding of the filler area
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- 3M™ Cubitron™ II 80+ - 120+
- To remove coatings more quickly, use the ROTEX motion setting
- To refine previous sanding scratches, switch to ROTEX orbital random motion, keeping the previous abrasive disc on the machine
Tip: Pre sanding step can also be done by using traditional body files if necessary.
Recommended products:
3M™ Hookit™ Cubitron™ II 80+ - 120+, 125mm
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Step 11 - Cleaning of the surface
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- Thoroughly degrease the surface
Recommended products:
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Optional - Second layer application
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- Apply a further layer of 3M™ FC Epoxy Metal Filler if nessessary and repeat drying and sanding steps as recomended in the previous steps
- Maximum finished thickness should not exceed 4-6 mm, maximum layer thickness should not exceed 2-3 mm
- Follow OEM and paint company recommendations for subsequent steps
Recommended products:
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Technical tips for removing a deep dent from a car panel
Here are some valuable insights into specific challenges surrounding repairing deep dents on car panels, including quick tips on preventing common issues such as....
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Holes and defects in the sheet when dent pulling
Customer Challenge:
Common methods for deep dent repairs can lead to defects and pinholes in modern steels and substrates, which are made these days from thinner sheet panels.
Technical Tip:
Welding equipment must be properly calibrated to avoid too much heat entrapment. Distribute the energy load across the whole repair area during pulling, to avoid any holes and overstretching of the substrate. -
Avoiding heat in grinding process
Customer Challenge:
The repair of damaged sheets of modern steels and high-strength steels in the outer skin of a vehicle can be problematic, because of their very special properties. Those types of steel are sensitive to thermal stress, which can negatively impact on the hardening properties of the steel.
Technical Tip:
Avoid introducing heat into the grinding process by using precise grinding tools such as Festool Automotive Systems Geared Eccentric Sander ROTEX in combination with 3M™ Cubitron™ II Abrasives Disc. This generates a better finish due to changed grain recommendation, reduced repair size and a better quality of the dent repair "from the start" with the goal of maintaining structural rigidity. -
Why not to use a 2K Polyester Body Filler
Customer Challenge:
Polyester resin fillers usually have less adhesion and worse mechanical properties than epoxy resin based products. Polyester fillers have hygroscopic properties and absorb water, which can lead to long term corrosion and delamination.
Technical Tip:
Using 3M™ FC Epoxy Metal Filler provides you with a non-hygroscopic filler with great adhesion to aluminium, steel and galvanised steel, which is able to seal any micro defects.
Watch Webinars Anytime Anywhere
Join the 3M Collision Repair Webinar Hub and hear first hand from our experts:
- New industry standards, new products and technologies
- Updated car repair standard operating procedures
- New design solutions for the collision repair industry
Discover more from 3M
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Haven't found what you're looking for? Or perhaps you would like to arrange a demonstration? Click here to get in touch!
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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 removing dents from a car panel. See our extensive range of solutions for all your car repair needs!
