Warning: That 'easy' hail damage job turned into a 3-day nightmare

Jennifer Lopez · 2026-03-28T08:15:05.135476+00:00

A customer brought in a Ford F-150 with what looked like minor dents, but the aluminum panels had hidden stress cracks. I spent two full days just on metal finishing before I could even start priming. Anyone else have a 'simple' repair that blew up on them?

margaretj406mo ago

Okay but "hidden stress cracks" sounds a bit dramatic. I mean, it's just some dents, right? Maybe the metal was already weak. Idk, I've seen guys fix way worse without it taking three days. Could it have been an overreaction to some tiny hairline stuff?

6

bettyperry6mo ago

Tell me about it. Aluminum body work always looks easier than it is.

4

alex_taylor106mo ago

Ever tried to weld a stress crack in aluminum? It's not just a tiny hairline thing, it spreads like a spiderweb once you start working the metal. @bettyperry is right, aluminum is a whole different beast. You chase one crack and two more pop up next to it, that's where the real time goes.

2