A couple of weeks ago, I found myself in the office of one of a group of 18 collision shops, training the office management
and staff on the finer points of management system use. During that training session, there happened to be a representative
of an insurance company conducting a drive-in at the facility.
I make it a point that while I am at any shop, I always try to be attentive and eavesdrop on the conversations going on around
me. I think it gives me a truer perspective of what happens during the "real" day-to-day operations of the shop.
This instance was no different.
Adhesives can now be used in many cases to repair roof panels. Photos Courtesy of Kevin Mehok
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In this particular case, the facility manager and the insurance company representative were discussing the finer points of
a proposed paintless dent repair project on the roof of a Toyota Prius. After some debate, an agreement was reached on the
PDR process and cost, and the discussion moved to other areas of damage.
Later that evening, while researching some repair data on one of my favorite technical resources, I remembered the conversation
that took place earlier that day and decided to look up the manufacturer's recommendations regarding roof repairs to the Prius.
I was very surprised when I pulled up Toyota's recommendations for PDR repairs. Basically, per this particular technical service
bulletin (TSB), Toyota did not recommend PDR repairs of any kind, on any panel, and if, in fact, repairs were undertaken utilizing
PDR, the vehicle's warranty would be voided. I couldn't believe it. I quickly realized that the bulletin was dated 1994, and
repair methods had evolved since then. Today, Toyota does recognize PDR repairs as viable, but only with certain stipulations
attached. I printed the TSB and brought it with me to the shop the next day.
Drill out the old roof welds before applying new ones.
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That event was a timely one since I was already in the process of writing this article, and it provided me a few more angles
to pursue in beginning to discuss roof repairs and replacement.
Construction basics
When replacing a roof, always cover the interior and remove the headliner.
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There are several different types of roofs used in the construction of the modern automobile. These include roofs with T-tops,
removable hard tops, sunroofs, retractable hard tops, convertibles, panoramic glass roofs and solid metal stationary hardtops.
Each one is unique in function and repair methodology.
Always trial-fit the new panel after making certain that all mounting flanges are straightened and properly aligned with the
replacement panel.
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The roof panel is one of the largest vehicle areas in square inches, covering the driver and occupant compartment or "cockpit"
of a vehicle. Obviously, it is an important part of the protective cocoon around the vehicle occupants. There are regulations
regarding the amount of damage a roof panel must be able to sustain without causing injury to a vehicle's occupants. Today,
a roof must be able to withstand a force 1.5 times the vehicle weight. Currently proposed legislation would require that a
roof withstand a force equal to 2.5 times the vehicle weight while maintaining sufficient head room for a buckled-in average-size
adult male to avoid being struck. It also would cover vehicles up to 10,000 pounds, versus the current 6,000-pound requirement.
As with all safety related repairs, you should never deviate from the manufacturer's recommended procedure regarding replacement.
Always consult OE specs when doing this type of repair. Let's look at one of the most common roof configurations that you
will see most often in the daily operation of your facility.
Posted 2009-01-01 23:33:11.0
