Why Aluminum Repair Requires Separate Tools and Workspaces

Aluminum has become a major material in today’s vehicle manufacturing. Automakers like Ford, GM, and many luxury brands are using aluminum panels and structural parts to reduce weight, improve fuel efficiency, and meet safety standards. While it’s a fantastic material for engineering, aluminum poses unique challenges in collision repair.

Unlike steel, aluminum requires its own tools, processes, and even workspaces. At Solon Collision in Aurora, OH, we’ve invested in the right equipment and training to ensure aluminum repairs are performed safely and OEM-compliantly.

Why Aluminum Is Different from Steel

Steel and aluminum behave very differently when damaged:

• No memory: Steel can often be pulled back into place. Aluminum doesn’t have that same elasticity — it cracks instead of bending.

• Heat sensitivity: Heating aluminum incorrectly can weaken it permanently.

• Corrosion risks: Aluminum reacts negatively if contaminated with steel dust, leading to galvanic corrosion.

Because of these differences, aluminum repairs must be approached with care, using methods specified by the manufacturer.

Why Separate Tools and Workspaces Are Required

One of the biggest mistakes some body shops make is trying to repair aluminum with the same tools they use for steel. This is a recipe for contamination and long-term failure.

• Dedicated tools: Sanders, grinders, and welders used on steel cannot be shared with aluminum. Tiny steel particles embed into aluminum surfaces and cause corrosion.

• Separate workspaces: OEMs require isolated aluminum repair bays to protect the material from steel dust floating in the air.

• Specialized welders and rivet guns: Many aluminum repairs require MIG brazing, bonding, or rivet-bonding systems instead of traditional welds.

At Solon Collision, we maintain separate equipment and processes to guarantee your aluminum vehicle is repaired the right way.

Common Aluminum Repairs

You’ll find aluminum in a surprising number of vehicle components:

• Hoods

• Doors

• Quarter panels

• Roof panels

• Pickup beds

• Structural frame components

Each of these parts has manufacturer-specific repair guidelines. For example, the Ford F-150 is built with a largely aluminum body, and Ford requires very specific tooling and repair processes to maintain warranty and crashworthiness.

Why OEM Procedures Are Non-Negotiable

Aluminum isn’t forgiving. Using the wrong technique can compromise strength and safety. That’s why OEM procedures always dictate:

• What type of bonding, riveting, or welding is allowed

• Where repairs are permitted vs. where replacement is required

• How corrosion protection must be restored

Shops that don’t follow OEM guidelines put drivers at risk — and often leave visible issues like corrosion or paint defects down the road.

FAQs About Aluminum Collision Repair

Why can’t aluminum be repaired like steel?

• Because it reacts differently to stress and heat, aluminum requires different tools and repair methods to maintain its strength and corrosion resistance.

Does aluminum repair cost more?

• Yes, because of the specialized equipment and training required. But cutting corners costs more in the long run.

How do I know if my vehicle has aluminum?

• Many newer models list aluminum content in their specifications. If you’re unsure, we can confirm for you during an inspection.

Final Thoughts

Aluminum repair is not a job for every shop. It requires dedicated tools, isolated workspaces, and OEM-trained technicians to ensure safety and durability.

At Solon Collision in Aurora, OH, we’re equipped and certified to handle aluminum collision repairs the right way. If your vehicle uses aluminum panels or structures, trust us to restore it to factory condition.

📞 Call 440-903-1009 or visit us at 260 Lena Drive, Aurora, OH 44202 to schedule your aluminum repair today.