Tool for removing dents from sheet metal

Abstract

A tool for pulling a dent out of a sheet metal surface has a support post with a foot shaped to rest against a portion of the sheet metal surface adjacent the dent. The tool includes a hinged lever arm which is pivotally connected to this support post at a lever arm pivot point which is elevated above the foot and adjacent sheet metal region. The tool also includes a pulling rod for coupling, through a fastener or connecting means, to the dented portion of the surface which is to be drawn-out, the pulling rod being connected to the hinged lever arm through a pivoting joint. The pivoting joint of the pulling rod and the lever arm pivoting point are positionable through actuation of the lever arm able to lie in a common plane which is substantially parallel to the sheet metal surface into which the dent is to be drawn into alignment. The pulling rod is adjustable in its engagement with the lever arm to permit the lever arm to swing through a limited angular range. Coupling between the pulling rod and lever arm is either discrete or continuous. Fasting means connecting the tool to the sheet metal include a self-tapping, self-drilling screw or a bolt provided with a magnetic washer or magnetic head.

1 . A tool for pulling a dent within a sheet metal surface into a plane which is generally in alignment with the surrounding sheet-metal surface, the tool including: 
 a) a support post with a foot with a face surface which is shaped to rest against an adjacent generally planar area of a sheet metal surface lying laterally to the dent;    b) a hinged lever arm which is pivotally connected to this support post at a lever arm pivot which is elevated above the foot;    c) a pulling rod for coupling, through a connecting means, to a dented portion of the sheet-metal surface which is to be drawn-out, the pulling rod being connected to the hinged lever arm through a pulling rod pivoting joint,    wherein the lever arm pivot and pulling rod pivoting joint are positionable during operation to lie in a common plane which is substantially parallel to the plane into which the sheet-metal of the dent is to be pulled.    
   
   
       2 . A tool as in  claim 1  in combination with a sheet metal surface to be worked wherein the lever arm pivot and pulling rod pivoting joint are positionable so as to be generally equally spaced above the sheet metal surface which is being worked.  
   
   
       3 . A method for using the tool as in  claim 1  wherein said lever arm is displaceable about the lever arm pivot by a range of movement of at least +10 degrees above said common plane.  
   
   
       4 . A method for using the tool as in  claim 1  wherein said lever arm is displaceable about the lever arm pivot by a range of movement of at least −10 degrees below said common plane.  
   
   
       5 . A method for using the tool as in  claim 1  wherein said lever arm is displaceable about the lever arm pivot by a range of movement of at least +/−10 degrees above and below said common plane.  
   
   
       6 . A tool as in  claim 1  wherein the pulling rod is provided with multiple apertures for engagement with the lever arm through the pulling rod pivoting joint, said pulling rod being positionable for alternate engagement by each of said apertures.  
   
   
       7 . A tool as in  claim 1  wherein the pulling rod comprises a ratchet means which allows it to engage with the lever arm at various degrees of extension below the lever arm.  
   
   
       8 . A tool as in  claim 7  wherein the pulling rod pivoting joint comprises a cylindrical seat and said ratchet means comprises an indented coupling edge which, is shaped to hook onto the cylindrical seat provided by the pulling rod pivoting joint, said indented coupling edge permitting the connection between the pulling rod and the lever arm to be progressively shifted upwards by one or more of the indentations after the lever arm is pulled through the range of a pulling stroke.  
   
   
       9 . A tool as in  claim 7  wherein said ratchet means comprises a continually adjustable coupling between the lever arm and the pulling rod.  
   
   
       10 . A tool as in  claim 9  wherein said continually adjustable coupling comprises: 
 a) a pawl-means in the form of a canting plate that has a tight-fitting opening through which the pulling rod passes,    whereby the canting plate will pass along said the pulling rod without an engagement with the pulling rod in one, first, direction when said plate is oriented transversely to the pulling rod, and will engage with the pulling rod at an angle when an attempt is made to advance the canting plate in the opposite, second direction.    
   
   
       11 . A tool as in  claim 10  comprising a resilient means that biases the canting plate to rotate into an angled orientation for engagement with the pulling rod when the canting plate is passed along said pulling rod in said second direction.  
   
   
       12 . The tool of  claim 1  in combination with a threaded sheet metal fastener having a central shaft comprising: 
 a) a threaded portion;    b) a seating shoulder to limit the penetration of the threaded portion of the post into sheet metal;    c) a necked-in region on said shaft to provide an engagement surface on the side of the shoulder remote from the threaded portion;    d) a larger terminating end connected to the necked-in region on the side remote from the threaded portion to provide an engagement shoulder for engaging the fastener, and    e) a self-drilling tip at the end of the threaded portion.    
   
   
       13 . The tool and threaded sheet metal fastener combination as in  claim 12  wherein the larger terminating end of the faster is shaped in the form of a bolt head for engagement by a bolt-turning tool.  
   
   
       14 . The tool and threaded sheet metal fastener of as in  claim 12  wherein the threaded portion is a self-tapping threaded portion.  
   
   
       15 . A method of pulling a dent within a sheet metal surface into a plane which is generally in alignment with the surrounding sheet-metal surface comprising engaging the sheet metal surface within the dent with a threaded sheet metal fastener having a central shaft and comprising: 
 a) a threaded portion;    b) a seating shoulder to limit the penetration of the threaded portion of the post into sheet metal;    c) a necked-in region on said shaft to provide an engagement surface on the side of the shoulder remote from the threaded portion;    d) a larger terminating end adjacent to the necked-in region on the side remote from the threaded portion to provide an engagement shoulder for engaging the fastener, and    e) a self-drilling tip at the end of the threaded portion    followed by the step of:    i) positioning the tool of  claim 1  with the foot against the adjacent sheet-metal surface and the pulling rod connected to the engagement shoulder on the larger terminating end of the sheet metal fastener, and    ii) actuating the lever arm to apply a pulling force to the dent so as to pull it towards alignment with the surrounding sheet-metal surface.    
   
   
       16 . A threaded sheet metal fastener having a central shaft comprising: 
 a) a threaded portion;    b) a seating shoulder to limit the penetration of the threaded portion of the post into sheet metal;    c) a necked-in region on said shaft to provide an engagement surface on the side of the shoulder remote from the threaded portion;    d) a larger terminating end connected to the necked-in region on the side remote from the threaded portion to provide an engagement shoulder for engaging the fastener, and    e) a self-drilling tip at the end of the threaded portion.    
   
   
       17 . A threaded sheet metal fastener as in  claim 16  wherein the terminating end is shaped in the form of a bolt head for engagement by a bolt-turning tool.  
   
   
       18 . A threaded sheet metal fastener as in  claim 16  wherein the threaded portion is a self-tapping threaded portion.  
   
   
       19 . A method of pulling a dent within a sheet metal surface into a plane which is generally in alignment with the surrounding sheet-metal surface comprising forming a hole within the dent and engaging the sheet metal surface through the hole within the dent with a fastener having a central shaft and comprising: 
 a) an enlarged head portion having a seating shoulder to limit the penetration of the central shaft through the hole;    b) a magnetized washer carried on said shaft adjacent said head portion; and    c) tool engagement means positioned on the shaft remote from the head portion,    followed by the steps of:    i) extending the shaft of the fastener beyond the hole into the region of the dent;    ii) positioning the tool of  claim 1  with the foot against the adjacent sheet-metal surface and the pulling rod connected to the tool engagement means on the fastener shaft, and    iii) actuating the lever arm to apply a pulling force to the dent so as to pull the dent towards alignment with the surrounding sheet-metal surface.    
   
   
       20 . The method of  claim 19  including the step of providing a further washer carried on said shaft on the side of the magnetized washer remote from the head portion wherein said further washer is larger than said magnetized washer.  
   
   
       21 . A welding fastener means in the form of sheet-metal plate having an opening form therein for engagement by-hooked coupling mean, said sheet-metal comprising a lower edge for welding to the surface of sheet-metal.  
   
   
       22 . A welding fastener as in  claim 21  wherein the length of the edge is in the range of 5 to 10 mm.  
   
   
       23 . A coupling means for engaging two or more welding pins for attachment by welding to sheet metal, said welding pins each having ends and said coupling means comprising: 
 a) multiple openings to receive the ends of said two or more welding pins; and    b) locking means for securing the ends of the welding pins into the coupling.    
   
   
       24 . A coupling means as in  claim 23  were in the locking means comprises set screws.