Has Anybody Successfully Repaired Dents In The Aluminum Tailgate Trim?

[AZ4X4SQBDY]

I've got a '87 GMC Sierra Classic pick up at the body shop right now and when it comes out it's getting all new bumpers and trim that is reproduced. I'm having difficulty finding a nice used rear tailgate trim panel, everyone of them is flawed. If it doesn't have a bunch of dents, then the  anodizing is faded or corroded. I've seen 2 "NOS" ones on an online auction site, both were shop worn and the one had damage, both sold for more than I cared to pay without physically seeing them first. GMC's are much more difficult to find than Chevy's.

I've gone on "You Tube" and have done some online searches for aluminum trim repair and have come to the conclusion that this isn't going to be a simple task. You must first remove the anodizing, then shrink the damaged area and make it straight, polish or sand the area, then reanodize it This is a little more than I want to get into at the house. I've also considered having a new one whittled out on a CNC or trying to cast one.

Has anybody successfully repaired or had theirs repaired?   
 

[80Chevy4x4]

I have successively been able to shape a piece of wood for both sides and then tap on them on the both sides and was able to get it straight without messing anything up....grant you this won't always work but if you try it and it works you haven't wasn't any money    plus you have a job done by you.....but if it doesn't work what have you lost? just a little time which we all waste time on our trucks...LOL

[AZ4X4SQBDY]

I have successively been able to shape a piece of wood for both sides and then tap on them on the both sides and was able to get it straight without messing anything up....grant you this won't always work but if you try it and it works you haven't wasn't any money    plus you have a job done by you.....but if it doesn't work what have you lost? just a little time which we all waste time on our trucks...LOL

I've carefully tried to tap some of the damaged area out but it cracks the anodization and turns the repaired area whiter than the surrounding areas. I've also thought about what you did, making basically a forming buck to move the sheet metal back into shape. An issue I've found is the metal actually gets stretched when trying to work the center brushed aluminum area. I've watched YT videos of how to work aluminum body parts, they heat it then quench it. The problem I've found when I tried this is it ruins the anodization.

[haroldwca]

The best solution I have found for restoring the anodized brushed aluminum trim we all love on these 73-87 trucks is to redo it with Everbrite Protecta-Clear.  I don't work for them and this is not an advertisement.  I've used it and it works.  Strip the old anodization.  I soak it with oven cleaner first, then hose it down.  After it dries, I do what ever repair is needed.  The smooth areas can then be polished with a buffing wheel and jewelers rouge (or similar product for soft metal).  The brushed finish is duplicated by linear sanding with 600 grit sandpaper and a VERY steady hand or some sort of guide.  Wipe it down with lacquer thinner, then follow the directions on Protecta-Clear.  It turned a RSW from a junkyard truck into what looked like a NOS piece.

[AZ4X4SQBDY]

The best solution I have found for restoring the anodized brushed aluminum trim we all love on these 73-87 trucks is to redo it with Everbrite Protecta-Clear.  I don't work for them and this is not an advertisement.  I've used it and it works.  Strip the old anodization.  I soak it with over cleaner first, then hose it down.  After it dries, I do what ever repair is needed.  The smooth areas can then be polished with a buffing wheel and jewelers rouge (or similar product for soft metal).  The brushed finish is duplicated by linear sanding with 600 grit sandpaper and a VERY steady hand or some sort of guide.  Wipe it down with lacquer thinner, then follow the directions on Protecta-Clear.  It turned a RSW from a junkyard truck into what looked like a NOS piece.

I have one that I have to strip the anodization because the heat crazed it when I tried to straighten it. I'll give it a shot. Thank you!!

I broke down and purchased a near mint used one. I paid more for this one piece than I've paid for a number of whole running and driving trucks I bought over the years. The market for these is getting nuts.

[Flyinhillbilly]

I've fixed a lot of aluminum trim when I was in the body shop business. I always annealed it before I worked the metal (which destroys the anodization) and worked it from there. The way I anneal aluminum is to fire up my torch on acetaline only and "smoke" the part with it, then I add oxygen to get the flame right and gradually heat it until the smoke burns off, then just let it air cool. It will be butter soft and really easy to work with. If it work hardens, just anneal it again.

[AZ4X4SQBDY]

I've fixed a lot of aluminum trim when I was in the body shop business. I always annealed it before I worked the metal (which destroys the anodization) and worked it from there. The way I anneal aluminum is to fire up my torch on acetaline only and "smoke" the part with it, then I add oxygen to get the flame right and gradually heat it until the smoke burns off, then just let it air cool. It will be butter soft and really easy to work with. If it work hardens, just anneal it again.

I've watched a couple videos on YT and when I get some free time I'll give that a try, I've got to get my tanks filled first. I don't think it's impossible, it's just a matter of doing it and practicing with it until you get the desired results.

Thanks for the reply!