Care must be taken to avoid stretching the metal during the forming operation. If the material is
stretched or if a proper backing device is not used, multiple hammer marks may be left in the
panel. This is unacceptable; it weakens the panel and does not restore its original profile.
(2) If a flat hammer and backing plate are used, the concave side of the dent should be supported by the
backing plate. The convex side of the dent is forced back into the flat surface of the backing plate
using the flat hammer.
Ball-peen or other round headed hammers must not be used.
(3) If any exterior surface coating is damaged during the repair operation, the affected areas must be
cleaned, masked, and primed. Apply a top coat to the exterior, notify Direct Support Maintenance.
Mid-Panel Patch Overlay
(1) Flatten the panel surface to remove distortion, wrinkles and creases. If necessary, cut away damage
until the surface is flat, leaving a smooth hole with even edges.
(2) Check foam insulation for moisture and damage.
If foam is damaged notify Direct Support
(3) Prepare a rectangular patch with rounded or chamfered corners to overlap the damaged area by 2
inches (50 mm) on all sides.
The patch material must be of the same specification as the damaged panel, and pre-painted if
the damaged panel is painted.
Clean and sand the portion of panel to be overlapped.