Aluminum Dent Removal in a Snowmobile Tunnel

This page works with the Aluminum Polishing page, but is limited to just removing dents.

Since filler cannot be used, we need to metal finish the aluminum

The "Dent"!

dent

 

Highlighted by sanding on it lightly.

dent

This was fairly stretched, so it wasn't extremely easy dent.  Since this is a rider, I just wanted to "minimize" the dent.

Starting to work the dent out.  Using small hammers, body hammers, and wood to support the back side when necessary.

dent

Using a block and sanding, you can see exactly where the high spots and the low spots are.  Getting closer.

 dent

By alternating which way you sand, you can see exactly what damage you need to work on.

dent

I left a few nicks in it.  It needs a little patina!

dent

Getting closer.  Working out the lows and high spots.

dent

And the finished product.

dent

dent

 

Tips:

 NEVER use sand paper or grinding wheels that were used on steel.  Pieces of metal can become embedded in the aluminum and cause rust stains.

Dress up and clean any body hammers.  Nicks will leave mars in the aluminum.

Work slowly using the sanded metal to show you your low and high imperfections

Heat can be used, up to 400 degrees.  This helps aluminum retain it's memory.

 

 

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