Warning: The way we handle aluminum panels changed for me after a 2019 job in Portland

I used to treat aluminum like steel, using the same grinders and heat. That changed when I had to fix a whole side on a new F-150. The heat warped it so bad we had to order a new panel. Now I use a low speed sander and keep a spray bottle of water handy to cool things down. What's your go-to trick for keeping aluminum flat?

4 comments

4 Comments

elizabethhayes2mo ago

Actually, water can cause aluminum to oxidize faster.

amy4832mo ago

Hmm, aluminum oxide forms a protective layer though, it's not like rust. Water alone doesn't really speed it up much.

the_zara2mo ago

So @amy483, does that oxide layer actually help with heat warping?

sarah8292mo ago

Remember watching my buddy try to weld a cracked intake manifold without enough heat control. He ended up with a puddle of metal and had to explain it to the customer. That was the day I learned to always use a heat sink paste on aluminum, even for small jobs.