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Technical What to do - Thick Bondo

Discussion in 'The Hokey Ass Message Board' started by 41Helen, Nov 18, 2021.

  1. PhilA
    Joined: Sep 6, 2018
    Posts: 2,061

    PhilA
    ALLIANCE MEMBER
    1. Hydro Tech

    Flap wheel is a bit harsh and can put a lot of unwanted heat into a panel.

    Best thing I've used so far for that and panel rust removal has been fiber abrasive discs:
    Screenshot_20211119-144017_Amazon Shopping.jpg
    Phil
     
  2. gene-koning
    Joined: Oct 28, 2016
    Posts: 4,040

    gene-koning
    Member

    Remove all of the old filler, the door may have already been patched before, and if the 1st patch seam is an inch higher then where you need to weld now, you would be pretty mad to discover you could have fixed the whole mess with your patch.

    You can metal work the door skin pretty good at some places, but other places, you really can't get to the back side very well. You get it as close as you can stand to deal with it, file it pretty flat so it looks pretty good, then start spreading that skim coat.

    I don't claim to be a body man, but I have done a lot of it. My problem with body work is I can only stand to do it for a short time. Its probably just my dumb ass, but once you start spreading filler and then sand, than add a little more filler and sand again, on an area as large as a door, its pretty hard to know how thick the filler really is. You can guess, but you really don't know unless you break through the filler and encounter metal. You can tell if you are really getting the filler thick, but for the most part, your not really sure.

    When the paint goes on, smooth is the goal. How much filler is really there probably isn't as important as how smooth the panel is. Gene
     
  3. Mr48chev
    Joined: Dec 28, 2007
    Posts: 33,861

    Mr48chev
    ALLIANCE MEMBER

    I'm going to have to agree with remove all of the filler and then work the panel as close as you feel you can get it before you weld the replacement piece on. With the bottom of the door removed it is real easy to sit there on a comfy stool and work the metal with a hammer and dolly. Work it down to that "thin skim coat surface and then weld the piece on remembering from all of those welding sheet metal threads on here to just do short tacks and space them so the metal doesn't get too hot and don't carried away trying to run long beads.

    As far as the thick plastic filler, that was standard used car stuff for years and may still be. Run it in the body shop, beat the big dents out so they are little dents and then lay on the pookie and use the cheese grater and air board to slick it off and shoot it and get it on the lot. Not a big deal and not the end of the world.
     
  4. KenC
    Joined: Sep 14, 2006
    Posts: 1,045

    KenC
    Member

    Me too, all the filler and paint comes off first. Then replace metal.

    On removing that stuff: I'm working on my 56 Dodge pickup and finding unexpected rust, old body work and lots of paint layers. The fiber stripping disk work better than flap wheels or sanding disks on areas without lots of paint layers. I've settled on a multi-tiered approach. On areas with lots of paint, looks to be mostly old enamel, hit it with a heat gun then scrape with a razor blade. Works pretty well on larger areas. And, what really surprised me is the easy of getting the filler off. A little heat, OK a lot of heat, and a putty knife. Right down to the metal with no dust on me,the floor or in the air.

    I follow the razor blade with 80 grit paper on a buffer, not grinder/sander. Less heat to clog the grit. Then the fiber disks in several sizes and shapes to get all the inside curves etc. The doors and jambs are particularly hard.

    The real point of the ramble is heat and putty knife is the best way I've found to get the filler off with the least mess.
     
    Tow Truck Tom likes this.
  5. oliver westlund
    Joined: Dec 19, 2018
    Posts: 2,352

    oliver westlund
    Member

    I dont find it generates much heat cutting the bondo. Thats why i said when you see metal back off. I guess to be clearer. When you see metal stop...it will cut through bondo in seconds. Ive never seen anything do better bit a lot of caution is definitely needed as well as a steady hand
     
    PhilA likes this.
  6. Way way Back in the Day I new a Guy that had a 50 Ford 2 door coupe
    that he wanted a Kustom car....................I guess you know where this Going.??
    Well he put so much on this car (bondo) that it was called the Bondo Car!
    When I had seen him I asked how the Car was & he told me he had
    A little Problem with the Car! & I asked what was wrong with it
    He said The car would not Run So I asked to pop Hood he Said No not
    That it Runs BUT IT Wont MOVE .
    From All the Weight from the Bondo it Wood Not Move, he had Fins that were
    about 1 & 1/2 Ft. tall of the back & extended the Fenders Front & Rear.
    I never Found out What happen to the Car Because I had to go in the
    Service, I got my Draft Notice & went away.

    Just My 3.5 cents

    Live Learn & Die a Fool
     
    41Helen and oliver westlund like this.
  7. 2Blue2
    Joined: Sep 25, 2021
    Posts: 378

    2Blue2

    I'm glad this car is getting fixed.
    Some full on Bondo sculpture.
    iu-17.jpeg
     
  8. Grind the bondo back about 3 in above where you want to weld, put wet towel on the remaining bondo to keep it cool and weld it up and bondo it up and go.
     
  9. Truckedup
    Joined: Jul 25, 2006
    Posts: 4,661

    Truckedup
    Member

    Yup, heat gun and putty knife...and a comfortable working position..
     
  10. mr.chevrolet
    Joined: Jul 19, 2006
    Posts: 8,860

    mr.chevrolet
    Member

    I sent you a PM about some 41 coupe doors i have for sale
     
  11. alchemy
    Joined: Sep 27, 2002
    Posts: 20,404

    alchemy
    Member

    Helen never came back. She forgot her password.
     
    41Helen likes this.
  12. goldmountain
    Joined: Jun 12, 2016
    Posts: 4,442

    goldmountain

    If you guys watch "cold war motors", a while back they did a segment where they "repaired" a rusty door with bondo. Absolutely hilarious.
     
    VANDENPLAS and 57 Fargo like this.
  13. 41Helen
    Joined: Sep 26, 2021
    Posts: 92

    41Helen
    Member

    So far I have been lucky. Body was set on a new frame. I did some repair already under the gas cap area, but other than that she is pretty solid.
     
    Dave Mc likes this.
  14. 41Helen
    Joined: Sep 26, 2021
    Posts: 92

    41Helen
    Member

    No, I am back. I just was on a work trip out of the country and was a little busy haha.
     
  15. 41Helen
    Joined: Sep 26, 2021
    Posts: 92

    41Helen
    Member

    I wish I would have done that on the first door. I learned my lesson though, the other side will be coming apart in 2 different sections, so I have a better reference.
     
    Squablow likes this.
  16. 41Helen
    Joined: Sep 26, 2021
    Posts: 92

    41Helen
    Member

    That's the rule of thumb I had heard too, but it just seems like SOOO much bondo.
     
  17. 41Helen
    Joined: Sep 26, 2021
    Posts: 92

    41Helen
    Member

    I did this the other night. So far all the spots I have checked have just a thin ski layer of bondo. Even the other door only had a skim coat, I think I just picked the wrong door to start with haha!
     
  18. 41Helen
    Joined: Sep 26, 2021
    Posts: 92

    41Helen
    Member

    This is the plan here in the near future. Just knock it all off and see what I am working with!
     
  19. 41Helen
    Joined: Sep 26, 2021
    Posts: 92

    41Helen
    Member

    This is what I am afraid of. My skills in this arena are raw and I know it's going to take me awhile to do it. I just want to do the car justice and finish it well.
     
  20. 41Helen
    Joined: Sep 26, 2021
    Posts: 92

    41Helen
    Member

    I feel your pain!
     
  21. 41Helen
    Joined: Sep 26, 2021
    Posts: 92

    41Helen
    Member

    HAHA! Yes, it's my fault and my fault alone. Thanks for the tips though, the fishtail really made easy work of this.
     
  22. 41Helen
    Joined: Sep 26, 2021
    Posts: 92

    41Helen
    Member

    This is exactly what I did, and it worked wonders.
     
  23. 41Helen
    Joined: Sep 26, 2021
    Posts: 92

    41Helen
    Member

    Thanks for this, it was really helpful!
     
  24. ems customer service
    Joined: Nov 15, 2006
    Posts: 2,634

    ems customer service
    Member

    not sure were you got panels from , you may want to try these
     

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  25. gary macdonald
    Joined: Jan 18, 2021
    Posts: 308

    gary macdonald
    Member

    Coarse wire brush on a angle grinder . Wear a mask ! Or heat and a scraper
     
  26. 57JoeFoMoPar
    Joined: Sep 14, 2004
    Posts: 6,138

    57JoeFoMoPar
    Member

    Those are my choice as well. They remove a lot of material quickly, don't put an excessive amount of heat in the panel, and leave a decent tooth in the metal for new filler to bite into. I've gone over even blasted cars with these just to prep the metal
     
    PhilA likes this.
  27. dave 62 pb
    Joined: Nov 5, 2013
    Posts: 252

    dave 62 pb
    Member

    I had the same with my truck, being an old farm truck all its life , the roof and hood were trashed as the farmer used to climb onto the hood then the roof to sheet over the grain in the tall dump bed
    The truck looked nice when i got it but i noticed the roof was dented on the underside so banged out the dent the bondo was 1" thick and some of the layers were still soft due to not having enough hardner mixed in
    I had to start over knocking out all the dents and shrinking the metal back before applying just a thin skim
     
  28. 41Helen
    Joined: Sep 26, 2021
    Posts: 92

    41Helen
    Member

    These are the exact ones that I bought! So far, I really like them.
     
    ems customer service likes this.
  29. Jacksmith
    Joined: Sep 24, 2009
    Posts: 1,564

    Jacksmith
    ALLIANCE MEMBER
    from Aridzona

    If those doors are any indication of what the rest of the car is like, the doors are the least of your problems. I'd pull them off & find replacements... go after the rest of the body in the mean time.
     

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