Drive Side Door Skin

Second post ever here, I think.

2005 Prius had some damage, left front fender and driver's door, summer 2008.

The Toyota dealership-owned body shop in Allentown PA did the body work.

First problem was, after the body work (skin replaced), was done, when the door was closed it sounded like a metal garbage can was dropped plus a rattling inside.

Took it back. They fixed the rattling.

Still when the door was closed it still sounded like a metal garbage can was dropped. I know this was not correct, this hollow sound. WHY? My 2006 Prius door did not sound like this at all.

I took it back and demanded they fix this. They did. No more can sound.

This car recently got some hail damage on the roof so I took it in to another body shop who, from prior experience, did good work. NOT the Toyota dealer body shop. The new shop points out what looks like hail dimples on the drivers door skin but they are evenly spaced and obvious.

Without a doubt, remnants of the Toyota shop work from several years ago.
I have noticed these dimples on the driver's door before but accepted that as somehow normal after door repairs.

Anyone have any idea what must have happened? Something to do with polyurethane on the inside is my guess but I cannot see internals. I'd post some pictures but it's too dark now.

Are these dimples to be expected?

Thanks

 

OK, "skin" is not the best use of words. Just my description. "Panel" it is!

They removed the driver door side panel and put a new panel on the original door frame. Work order even lists the part number as 67112-47020. Google this number. Called it "Panel. FR DOOR. O"

If you have a manual look up BP-36, BP-37. I secured a copy I took with me on the last visit to show the Toyota body shop experts the instructions in case they weren't clear on how to get everything back together again correctly. I was enduring first the rattle+ tin-canning, next the tin-canning. I was not being a smart a** but after two visits already I was unsure if they knew what they were doing. Manager was p.o.and said the tech who did the job was no longer working there.

Polyurethane, according to the instructions, is used to glue the new panel to the reinforcement and side impact beam.

After this last job, and couple hours sit, the car smelled of organic chemical fumes as I drove home.

Just trying to see if anyone else has had a similar experience and of course, if the dimpling is normal.

 

I come from an aviation background so "skin" is what's either riveted or "glued" onto ribs.

I too hadn't heard of this repair method.

I believe they grind off the edges, the "hemming location" of the old panel. Picture on BP-36 shows a disk grinder. Then peel it off. Then attach the new panel with a special crimping tool called a hemming tool.

Pictures on BP-37 references what appears to be numerous places to apply polyurethane foam, I guess, as a glue.

What can be seen in my picture are 4 dimples. Under certain viewing angles they are as plain as day reminding me of fish eyes. Daughter has mostly used this car while away at college so I hadn't noticed how obvious it is. And it does seem to be more obvious now than ever, as if, it's getting worse.

Having just picked it up from the other body shop for the hail damage, wife asks "why didn't they fix the hail dents in the door"? That did it. I had to know if this is to be expected.

Insurance company, as they paid the original claim, will be informed as will the body shop that did this. I am sure there will be a confrontation. Time has gone by yet I am sure they will remember my 3 total visits on this door. I have only to ask anyone tuned in, "am I being anal"? Or should I expect it to be done right, if right means, no obvious dimples?

 

This is my guess. Of course I couldn't see what they were doing but think the first visit either they didn't apply the polyurethane at all or not enough. What could have caused the rattling?

Will do. First here's something I was not aware of until calling the insurance company about this, seeing they paid the bill. The original damage was front left fender and driver's door. Daughter and garage door frame This is what I sent to some friends in email.

"You all know when it comes to auto body repairs on your car, when making an insurance claim, you can take your car wherever YOU want? True.

"Did you know that if you make this choice, and NOT use the insurance company's choice, then later have to have work redone, the insurance company takes no responsibility?

"With their choice of auto repair shop, they will go to work for you and enforce the warranty for life of the car.

"If you exercise your choice of auto repair shop, they will not help you if the shop gives you are hard time. It is your battle to fight alone.

"I have a car that had a door external panel replaced a couple years ago. Long story short, I had to take the car back two additional times, after the first visit to quiet down the rattling sounds and boom (like dropping a metal garbage can).

"Thought this was the end of it. Increasingly I have noticed 4 dimples on the door resulting from something they did. You can see it in the picture I added. It needs to be done correctly.

"We chose the local Toyota dealership auto body shop because the car is a Toyota. Shouldn't they be the best choice, someone who knows the car and has better access to parts? That's what we assumed.

"So happens, as I learned today, according to my insurance company, Allstate, the Toyota shop was not their choice. Their choice has to be part of something called the Pro program.
Shop here is a national network, Sterling.

"Off their website:
These repair shops meet strict quality standards and Allstate guarantees that the workmanship of the covered repairs performed by an approved shop will meet auto body repair industry standards. If you choose an Allstate Good Hands® Repair Network shop, the shop will work directly with the adjuster, file the paperwork, and guarantee the work for as long as you own your vehicle.

"Therefore I have to work this out entirely on my own.

 

A friend in the insurance business for 30 years said an insurance policy is a contract.
It's our responsibility to know what's in the contract. Buyer beware! Said most insurance companies do it this way.

Said the dimples looked like spot welds. Who knows? We don't get to watch. Now if so, welds, I cannot see how this old panel can be easily peeled off. A whole new door? All guessing now.

He said a reputable shop will fix this. Toyota will do the right thing. We shall see. I have some things to challenge today.

 

It's hard to tell. The magnet sticks everywhere.

What's difficult about all this is, from some viewing angles, you cannot see any blemishes. You have to run your fingers slowly over them to feel a slight depression. Other angles, as in the picture, obvious. Best seen under lighting that's not so bright. I think because of the reflective quality of the paint.

I am not so sure about bondo. Here's why. The second and third visits were of half-day durations. The metal rattling was tackled on the second visit. That stopped. Would not have been time enough to paint and clear coat. Paint, I doubt, was ever touched again after the panel was first put on.

My guess is, each of the second and third visits, either they 1. spot welded in 4 spots then 2. deadened the sound. OR 1. glued the panel in 4 spots, then 2. deadened the sound.

Fun analyzing but I should have what really happened shortly..

I visited the General Manager of this Toyota dealership (not the body shop), showed him the picture. He didn't need to see the car outside. Apologized, said that body shop manager isn't there anymore and they will do right by me!!!

Ask if I'd be satisfied with "paintless dent repair". I said, if it works, no problem.
But explained why I think it won't work. Tomorrow, I should see a fellow who will look inside and determine what's what.

Let me say, loud and clear, Toyota and this dealership are, without hesitation, taking care of me. My fears of a struggle are unwarranted. So far so good.

Remains a Toyota fanboy. Feeling pretty good.

My electrical engineer vegetarian daughter in Silicon Valley, who now owns my 2006 Prius, sent me this. Enjoy
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