A method of developing a repair process for a gas turbine engine component deformed during engine operation includes determining peak stress locations in a model of the component, applying loads to sample components based on the model to produce geometrical correction values in the samples, generating data from the samples including the loads applied and the geometrical correction values produced, destructively analyzing the samples at the peak stress locations for structural imperfections, and correlating the loads applied to the geometrical correction values produced to determine allowable loads necessary to produce target geometrical correction values in a used component substantially free of structural imperfections.