Specialist panel beating tools

Panel puller
This tool (Figure 3.12) comprises a long steel rod with a cross T-piece at the top which acts as a hand grip. At the other end a fixed hexagonal nut holds a strong self-tapping screw,while a heavy cylindrical weight can slide up and down the shaft against a stop which is near the handle. This tool has been designed to pull out dents and creases from the face side of the panel without the necessity of removing the trim and lining materials to gain access behind the dents. It can also be used on double-skinned panels where access is impossible with conventional tools.

The panel puller is used by drilling a in (3.175mm) diameter hole at the deepest part of the dent,then inserting the self-tapping screw in the hole and screwing it until a firm grip is obtained. One hand holds the T-bar while the other pulls the sliding weight towards the stop; there the weight rebounds,forcing the dented panel out under the impact of the blow.

Zipcut spot-weld remover
The Zipcut spot-weld remover (Figure 3.13) is used with an electric or air drill,and is ideal for removing spot welds on all areas of bodywork andsubframes. The cutter blade A is reversible with two cutting edges. Adjustment B provides forvarying depth ofcut so that only the upper panel is released (c),leaving the original spot weld behind on the lower panel.

Cone drills or variable hole cutters
These are special alloy steel drill bits which havebeen hardened to give a fine cutting edge (Figure 3.14a). They are shaped like a cone and fit in the chuck of a standard power drill. The hole diameter can vary from 6 to 40mm depending on the hole cutter in use. These cutters are used for fitting wing mirrors,aerials and rubber grommets into body structures.

Cobalt drills or spot drills
These are special alloy steel drills to which cobalt has been added to give a very hard sharp cutting edge (Figure 3.14b). The design of the cutting edge allows spot welds to be drilled out of panel assemblies without creating any panel distortion.
Impact driver
The impact driver (Figure 3.15) will loosen or tighten the most stubborn screws,nuts and bolts. The tool is supplied with a complete range of interchangeable bits.

Body trim tool
This is a universal spring steel tool for removing body trims and clips,and also weather strips,door trims,headlamp fittings,windscreen clips,plastic mouldings,motifs and badges (Figure 3.16a).
Door handle spring clip removers
These are specially designed pliers for fitting orremoving the spring clips used on many modern door handles. One jaw sets in the neck of the spring whilst the other grips the other end,and the whole spring is then levered out (Figure 3.16b).
Trim panel remover
This tool is designed to remove vehicle trim panels,upholstery and roof liners without damage (Figure 3.16c). It also fits a wide variety of buttontype fasteners used on vehicle trim.
Door hinge pin remover and replacer This is designed for the removal and replacement of hollow hinge pins used on vehicle door hinges (Figure 3.16d).

Corrosion assessment tool

This tool has been designed for vehicle inspec- tion(Figure 3.16e). It acts as a combined tapping hammer,blunt scraper and short lever. It has been introduced to standardize the methods of corrosion assessment employed by MOT testers,and is ideal for bodyshops conducting pre-MOT checks and assessment for corrosion.
Bendable file
This tool is a standard round file but it can be bent to the desired shape,which allows it to be used indifficult locations where a normal straight file would not have easy access (Figure 3.16f).
Clamps Sheet metal clamp (Figure 3.17a) is a general- purpose clamp which can be locked on to sheet metal with a powerful quick-release grip,making panel assembly and tack welding procedures much easier operations.

 
Welding clamp (Figure 3.17b) has a powerful grip which holds parts in alignment while leaving bothhands free for the welding operation. Thedeep-throated jaws and centre opening provide the operator with maximum visibility and full access to the welding area. C clamp (Figure 3.17c,d) has a wide jaw opening with a relatively small gripping area,which pro- duces pressure without permanent jaw damage to panel surfaces. It allows accurate close-up working in restricted areas and on awkward shapes,e.g. sill panels.
Punches
Hole punches (Figure 3.18a) have interchangeable heads to punch holes of either3/16 in (5mm) or in (6mm) diameter,and enable joining panels to be accurately aligned for welding. The3/16 in (5mm) diameter hole is for gas welding or brazing and the1/4in (6mm) hole is for MIG welding.
Wing punch (Figure 3.18b) is a hole punch with aspecially designed head which allows it to be usedon wing panels and channel sections and also fitover roof gutters and wheel arches.
Edge setters
The edge setter (Figure 3.19a) is a portable,handoperated tool designed to provide a ‘joggled’ joint or stepped edge on a repaired or new panel,thuscreating a flush-fitting lap joint. The joggled panel edge provides a stiff joint and helps prevent distortion when welding. It can be used on mild steel up to 1.2mm (18 gauge) and applied in many situations which require this type of joint.
The rolastep edge setter (Figure 3.19b) is aportable tool used on the vehicle or a panel assembly. Its rollers produce a smooth,uniform stepped panel edge to create a flush-fitting lap joint,allowing a panel replacement to be inserted.

Door skinner
This is a special tool (Figure 3.20) for crimping flanges tightly on replacement door skins. It is used by first bending the flange to an acute angle and then tightening or crimping the flange to the door frame. During this operation,interchangeable tough nylon pads prevent damage to the surface of the door skin.

 Inter-grip welding clamp
The inter-grip clamp is approximately 25mm cube shaped,and uses a wing nut and toggle bar to firmly clamp pieces of metal together edge to edge and perfectly level,leaving only a small gap which will allow full penetration of the weld and filler rod (Figure 3.21). Once the two sections are tack welded together the wing nut is slackened,the toggle bar removed and the clamp lifted from the job,prior to final welding. The end result is a firstclass butt weld requiring very little dressing. The clamps are ideal when welding patch repairs in floors,wings and door skinning,or when assembling fabricated or new panels.

Temporary sheet metal fastener system
This sheet metal holding system is a set of pins, installed with special pliers,which quickly and easily clamps panels together before final welding, bonding or riveting (Figure 3.22). The clamps will securely hold together body panels and sections where no other clamp will reach because there is no rear access. The 3mm blind fasteners have an expanding pin which,when inserted through the panel and released,exerts over 8kg (18lb) holding pressure. The edge grips have 12mm deep jaws to clamp flanges and other edge work. To install or remove either,the pliers are needed to overcome the powerful spring pressure.