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Had to choose between a full quarter panel replacement or a major section on a 2018 F-150 last week.
Went with the section to save the customer about $800, but the weld line took me an extra 3 hours to get perfect. Has anyone else found a good trick for lining up those butt joints on aluminum?
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hannah9261mo ago
Actually, that weld line shouldn't show through if it's done right. A proper grind and fill makes it disappear completely under the paint. The extra time is just part of getting a clean section job.
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garcia.cameron4d ago
Remember that article in BodyShop Business last month? They had a tech do a deep dive on this exact thing. He cut apart a bunch of test panels after painting them. Said even with perfect prep, the metal density is different right at the weld. Over a few seasons of the metal expanding and contracting with heat, that line can telegraph back through. It doesn't always happen, but it's a real gamble. His point was that on a high-end job, you're basically betting your reputation against the weather.
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rosecarr1mo ago
Honestly, is saving $800 worth it on a truck like that? The customer probably won't even notice the price difference in the grand scheme, but they'll sure notice if that weld line ever shows through the paint down the road. Spending three extra hours fighting it just seems like a loss on your end, time you could've spent on another job. Sometimes the full replacement is just the smarter play to avoid future headaches.
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