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Handling / Mounting
Handling and Mounting Automotive Parts During Collision Repair
Table of Contents
Introduction
Once a panel is removed from the vehicle, the way it behaves in the body shop changes immediately. On the car, the surrounding vehicle structure supports the panel, keeps it aligned, and holds it at a workable height. Once removed, that support disappears and the part becomes a loose component that must be mounted somewhere while technicians carry out repair, preparation, refinishing, or reassembly work.
In a collision repair shop this applies to a wide range of parts. Bumper covers, doors, fenders, hoods, tailgates, mirrors, trim pieces, and wheel rims all pass through the workshop as individual components at different stages of the job. Some are large and flexible, while others are compact but awkward to secure.
Handling these parts correctly is not simply a matter of convenience. Poor mounting can make panels unstable, increase the risk of damage, and force technicians to repeatedly reposition components as work progresses. Proper mounting allows the part to remain stable, accessible, and balanced from the moment it leaves the vehicle until it is reinstalled.
Handling Challenges
Different automotive parts present different mechanical challenges once they are removed from the vehicle.
Bumper covers are among the most difficult components to handle. Most modern covers are large plastic shells with very little structural rigidity. Their mounting points are typically thin tabs designed only to locate the bumper against the vehicle structure. When the bumper is supported by only one or two of these tabs, the entire piece can flex, twist, or sag under its own weight.
Doors present a different challenge. Compared with bumpers, they are rigid and heavy. A complete door assembly may include glass, window regulators, reinforcement beams, wiring harnesses, and trim components. The weight is often concentrated near the hinge side, creating an uneven load when the door is mounted on a stand.
Hood and bonnet panels are large but relatively thin. Their outer skins can flex easily if they are supported only at the corners. Because of their width, technicians must also consider working height and reach distance. A hood mounted too high forces technicians to stretch across the panel, while one mounted too low encourages bending and awkward posture.
Fender panels are lighter but often have irregular shapes with narrow mounting flanges. These flanges were designed to bolt to the body structure, not to carry the entire weight of the panel on a stand. If the fender is hung from a single bolt hole or bracket, it may swing or vibrate when touched.
Tailgates and hatch panels combine several of these challenges. They are large assemblies that often contain glass, wiring, and internal trim. Depending on the configuration, the center of gravity can shift significantly, making the panel difficult to balance when mounted.
Small components such as mirrors, trim pieces, and brackets create another type of handling issue. These parts may not weigh much, but they often rely on delicate clips or plastic tabs that can easily be damaged if stressed during mounting.
Wheel rims, although compact and rigid, present their own handling challenges. When placed flat on a bench they occupy space and can roll or shift easily. Supporting them securely prevents movement while technicians are working nearby.
Common Mounting Mistakes
Many mounting problems in body shops occur when technicians attempt to secure parts quickly using whatever attachment point is easiest to reach.
One of the most common mistakes is hanging large parts from weak mounting tabs. This frequently occurs with bumper covers and plastic trim panels. The thin tabs along the edges of these components were never designed to support the full suspended weight of the panel. When supported in this way the tabs can deform or crack, especially if the part is moved around the workshop.
Another frequent issue is using too few support points. A door hung from a single hinge bracket or a hood supported at only two corners will never be stable. The panel shifts whenever it is touched, forcing technicians to constantly reposition it.
Balance problems are also common. When a heavy component is mounted without considering its center of gravity, it will naturally rotate toward the heavier side. Doors often tilt toward the hinge area, while tailgates may lean due to the weight of the glass.
Incorrect working height is another overlooked problem. Parts mounted too low cause technicians to bend forward repeatedly, while parts mounted too high require extended reach and awkward shoulder positions. Over time this slows work and increases fatigue.
Technicians may also mount parts in ways that block access to important areas. A fender clamped tightly across its mounting flange or a bumper supported across its face may prevent access to edges, brackets, or attachment points that still require work.
Correct Mounting Approach
Proper mounting begins with one simple principle: the component should be supported in a way that distributes its weight across several stable points rather than relying on a single attachment.
Large plastic components such as bumper covers benefit from wide support spacing. Instead of hanging the bumper from one central bracket, the panel should be supported across multiple points along its length. This keeps the bumper closer to its natural shape and prevents sagging.
Doors should be mounted using strong hinge mounting points or reinforced structural areas designed to carry weight. Supporting both hinge locations helps distribute the load evenly and prevents the door from rotating toward the hinge side.
For wide panels such as hoods and tailgates, stable support should be created along both sides of the panel. Supporting the hinge areas while adding secondary support points along the outer edges helps distribute the load and reduce flex.
Fender panels benefit from support that stabilizes the mounting flange while also preventing the lower section of the panel from swinging.
Small components should be secured in ways that avoid stressing fragile clips or decorative surfaces. Mounting through stronger internal brackets or structural areas provides better stability.
Equally important is positioning the part so technicians can comfortably access all working areas without repeatedly repositioning the stand.
Body Shop Workflow Considerations
In a busy collision repair shop, parts rarely remain in one place. After removal from the vehicle they may pass through several stages including inspection, structural repair, surface preparation, refinishing, curing, and storage before final reassembly.
Mounted components often move between different areas of the workshop during this process. A bumper may travel from a repair area to preparation, while a door may be moved into the refinishing booth. Smaller parts may be stored temporarily while other work continues on the vehicle.
If a component is poorly mounted at the beginning of this process, technicians may need to reposition it repeatedly as it moves between work areas. Each repositioning wastes time and increases the risk of dropping or damaging the part.
A properly mounted component can remain on the same stand throughout most of the workflow. The stand moves with the part between workstations while keeping it stable and accessible. This reduces handling, improves efficiency, and helps protect the component during the repair process.
Equipment Used
Collision repair shops typically use several types of equipment to support removed panels and components.
Adjustable panel stands are commonly used for doors, hoods, tailgates, and fenders. These stands allow technicians to position mounting arms at different heights and widths so the stand can match the size and shape of the part being supported.
Bumper stands are designed specifically for large plastic bumper covers. They provide wider spacing between support points and often include padded contact areas to prevent distortion while the bumper is mounted.
Small parts stands are used for mirrors, trim pieces, brackets, and other compact components. These stands allow multiple parts to be mounted securely without cluttering workbenches.
Wheel supports or rim stands hold wheels vertically or horizontally so they remain stable while technicians work around them.
When used correctly, these types of equipment help keep removed components balanced, accessible, and protected as they move through the repair process.
Related Equipment
Equipment commonly used for handling automotive panels includes: