Accounting for seam repairs on panels
Quarter panel replacement on a 2008 four-door sedan has labor of 16.5 on the estimate. There will be a welded seam at the roof panel, rocker panel and rear body panel. Welding operations are part of the 16.5 labor. Each of those seams may be finished differently. How does your estimating system handle those? What is included? What do you need to add?
Consider these three areas or steps in the process: repair of the welded joint, feather, prime and block of the area, and refinish of both panels. The roof panel seam is completely exposed. It must be invisible and refinished to the same level, color and texture as the undamaged panels. The rocker panel seam is partially exposed. It still must look good and be refinished properly even if partially covered by trim and a closed door. The rear body panel seam will be hidden so metal finishing and painting will not be seen.
For repair of welded joints, Audatex states, "Replace labor does not include additional labor to repair the replaced panel and or adjacent panels which may become distorted, burned or damaged by welding, drilling, grinding and straightening." Replacement procedures for a quarter panel include body fill labor, block sand, application of guide coat and dual action sand.
MOTORS (CCC) procedures says, "Grind, fill & smooth welded seams (up to 150 grit sandpaper)" are included operations. Mitchell's procedure pages explain, "The labor times for welded panels include grinding, filling and final sanding with up to 150 grit sandpaper to match the original panel contour."
All estimating systems include repair work to smooth out normal weld joints. Audatex does not include repair of damage due to the welding process but includes all operations needed to repair the welded seams up to a level for refinishing.
MOTORS specifically does not include "welded seam surface finishing finer than 150 grit sandpaper." This leaves a gap between the end of repair and the start of refinishing. That gap is commonly called feather, prime and block. This operation brings a repaired surface (typically 150 grit according to a CIC statement) to a new panel surface level. This is where pre-stored refinish labor times begin.
For welded panels, Mitchell states, "Labor times do not include the feather, prime and block refinish operation." For exposed seams, both MOTORS and Mitchell procedure pages support the need for additional feather, prime, and block labor time. For hidden seams, this operation may still be necessary to match the factory appearance as part of a fully undetectable repair.
Refinish of the replaced panel does not include refinish of any adjacent panels. With a fresh weld seam, adjacent panels will need refinishing. What else do they need? Audatex base refinish labor "does not include additional time to refinish adjacent panels that may be damaged by welding." Replace labor includes body fill labor, block sand, application of guide coat, and dual action sand which may or may not include sufficient preparation for refinishing panels on both sides of the seam, depending on any weld damage.
MOTORS states, "Suggested refinish operation times do not include additional time for repair of damage to adjacent panels resulting from normal cutting, welding and grinding procedures."
Mitchell's not-included operations state, "Feather, prime and block paint damage to adjacent panel and/or panels joined by welding due to burn damage."
Because a weld-on panel attaches to existing vehicle panels, additional refinishing beyond the replaced panel will be needed. Just remember that pre-stored refinish labor for a panel begins with a new panel surface. Be clear on your estimating system's procedures. Be clear on your repair procedures. Be clear on your estimate. Before refinishing, body panels - whether with straightened metal or welded seams - need repairs up to the level of a new panel surface. Be sure estimates contain all needed operations.
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