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Body Work 101

Discussion in 'Body Work & Detailing' started by MONMIX, November 7, 2004.


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    1. MONMIX

      MONMIX I fix dents Staff Member Moderator Elite Explorer

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      mud.jpg To begin Bondo is a product name for body filler.
      I am not a fan of Bondo products.
      I use Evercoat Rage Gold and Evercoat Metal Glaze.
      It is a far superior body filler.
       
      Last edited: November 7, 2004
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    3. MONMIX

      MONMIX I fix dents Staff Member Moderator Elite Explorer

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      dent.jpg Here is the dent the day it happened.
      It is my assumption the Ex was shot with a pellet gun, seemingly aiming for the window.
      Ugly. If you look at the reflection, you can see the dent is approximatley two inches
      in diameter.
       
    4. MONMIX

      MONMIX I fix dents Staff Member Moderator Elite Explorer

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      dolly.jpg The dent was so close to the glass I removed both the glass and the trim so it would not get
      damaged in the repair. I used several layers of masking tape to protect the rear glass.
      The first step is to flatten the metal as much as possible. The thinner your mud ( body filler )
      goes on the better. 1/8th of an inch is ideal, I would not go more than 1/4inch.
      A stud welder is pricelss in body repair, however I try to use them only as a last resort.
      This dent was an easy fix by just working the metal.
      I had a buddy hold the flat side of a metal toe dolly flat on the out side of the dent.
       
    5. MONMIX

      MONMIX I fix dents Staff Member Moderator Elite Explorer

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      punch.jpg I crawled inside the Ex and with a hammer and blunt point punch, and lightly tapped the dent outward.
      It took only a short period of time, tapping in several locations, is several directions.
      Nine times out of ten, it is best to work the dent out little by little to minimise stretching.
       
    6. MONMIX

      MONMIX I fix dents Staff Member Moderator Elite Explorer

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      flat.jpg
      You can see the dent is MUCH flatter than previously. With out question, the flatter the better.
       
    7. MONMIX

      MONMIX I fix dents Staff Member Moderator Elite Explorer

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      grind.jpg
      With a 36 grit disc on a grinder I removed ALL the paint one inch beond the damaged area.
      36 grit is ideal because it is not so agressive it removes too much metal, but it does leave
      deep scratches for the mud to grab a hold of. Note the thinning edges. Grinding the edges this way makes feather edging much easier.
      Make sure you clean the area very well with compressed air. Dirt is your enimy.
       
    8. MONMIX

      MONMIX I fix dents Staff Member Moderator Elite Explorer

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      filler.jpg Here is a dab of body filler with hardener. Note the ratio, also note the " Clean Sheets " mud board.
      Mixing on cardboard is not a good idea because cardboard is fiberous and you can pick up little " hairs "
      in your mud. Again, dirt is your enimy.
       
    9. MONMIX

      MONMIX I fix dents Staff Member Moderator Elite Explorer

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      mix.jpg
      Here you see me mixing the mud. Note I am NOT stirring. You basically want to criss cross the mud and hardener, like you are spreading it onto the mud board. You can also see I am pressing down onto the board to push out the air bubbles. Air bubbles become pin holes. Note also I am NOT a Smurf, they are protective rubber gloves. Body filler is messy and will make your hands ugly for a few days.
      When you get done spreading the mud CLEAN your spreader !!!!!!!!!!!!!!!!!!!!!!!
      Use some thinner. Treat this fifty cent piece of plastic like a $100.00 tool.
      Keep it spotless and don't let the mud dry on the spreader.
       
      Last edited: November 8, 2004
    10. MONMIX

      MONMIX I fix dents Staff Member Moderator Elite Explorer

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      fill.jpg
      Put the mud on thick. The body filler really doesn't like to stick to paint, so keep it on the bare metal.
      Let it dry. It should be hard and NOT tacky. Cold weather could take as much as ten to fifteen minutes
      hot humid days less than three minutes
       
    11. MONMIX

      MONMIX I fix dents Staff Member Moderator Elite Explorer

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      mask.jpg
      Before we start sanding the mud, a dust mask is EXTREMELY important.
      Wear one when sanding. They are mere spare change each.
       
    12. MONMIX

      MONMIX I fix dents Staff Member Moderator Elite Explorer

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      sand.jpg
      Start sanding with a small sanding block with 80 grit paper.
      Sand up, down, left, right, and diagonally. Don't just go hog wild.
      Sand across one way going all the way across the mud evenly with light pressure.
      Smooth, even, consistant strokes.
       
    13. MONMIX

      MONMIX I fix dents Staff Member Moderator Elite Explorer

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      done1.jpg
      The end result every thing should look like a cloud. Note how the edges have smoothed out.
      You can also see the different layers of paint fade away the clear, the color and then the primer.
      Ideally you want it to fade away. This is a feather edge. The longer and the smoother the feather edge the better.
      It may take more than one coat of mud.
      You may have low spots you need to refill, you may have high spots you need to tap down with a small punch.
      Take your time, and do not rush.
       
      Last edited: November 9, 2004
    14. MONMIX

      MONMIX I fix dents Staff Member Moderator Elite Explorer

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      skim.jpg
      Skim coat, also called top coat or metal glaze is thinner and runnier that body filler.
      This stuff is NOT very effective at dent filling. It is designed to fill pin holes and scratches. That being said, make sure your filler mud is 100% correct.
      Meaning, it is smooth, and had has the correct shape. Skim coat is intended for a finishing coat. If you need more than two coats of skim, you may have put it on too soon. This stuff will cling to a painted surface as long as it has at least 180 scratches.
       
      Last edited: November 9, 2004
    15. MONMIX

      MONMIX I fix dents Staff Member Moderator Elite Explorer

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      spread.jpg
      Press this stuff on the panel, you want to make sure it fills the scratches and pin holes.
       
    16. MONMIX

      MONMIX I fix dents Staff Member Moderator Elite Explorer

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      skimon.jpg
      Go into the feather edge when spreading this stuff.
      I start sanding this with 80 grit, but as soon an the " shine " goes away in the skim, I step
      up to 180 grit.
       
    17. MONMIX

      MONMIX I fix dents Staff Member Moderator Elite Explorer

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      feel.jpg
      Feel the mud work often. Hand flat, light pressure, finger tip to palm, smooth straight motions.
      Close your eyes and / or look away. Other than texture from the painted area to the repaired area you should feel no waves, bumps, or edges. If you do, sand some more, or re-coat if necessary
      If you are having a hard time feeling the work, some times it can help to have a thin tee shirt between your hand the the work.
       
    18. MONMIX

      MONMIX I fix dents Staff Member Moderator Elite Explorer

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      done2.jpg
      This is what the finished product should look like. Again it looks like a cloud. There is
      no sharp of drastic changes or edges.
       
    19. MONMIX

      MONMIX I fix dents Staff Member Moderator Elite Explorer

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      DA.jpg
      Hit it with a soft pad DA ( dual action ) sander with 320 grit. Note the thick soft pad on the DA.
      This soft pad will not alter the mud work. You want to make all the 180 grit scratches go away.
      Be careful in this stage. You just want to smooth the scratches. Make sure you go beyond
      your original work area with the 320 scratches.
       
    20. MONMIX

      MONMIX I fix dents Staff Member Moderator Elite Explorer

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      prime.jpg
      Cover the truck in a plastic bag and prime. I put three coats on this one.
       
    21. MONMIX

      MONMIX I fix dents Staff Member Moderator Elite Explorer

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      coat.jpg
      Before you call it a day, make sure you spray some undercoating on the back of the metal work.
      You can see in my metal work photo I scratched the inside of the metal pretty well. Let the prime dry over night.
       
    22. MONMIX

      MONMIX I fix dents Staff Member Moderator Elite Explorer

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      preped.jpg
      Here the Ex is totally de-trimmed. All the glass is out, wheel flare off, tail light off, rocker trim off.
      ( body side mouldings were removed ages ago ) With a flat sanding block sand the primer smooth with 400
      grit. Make sure you smooth the edges so that you can not feel a thing.
      Wipe down the whole quarter panel with thinner to remove the wax and crud.
      Scuff the whole panel with a 3M red scotchbrite pad.
      Blow it clean with compressed air, and wipe it down with anti static degreaser.
      Dirt is even more your enemy now.
      This panel can not be clean enough from here on out.
      Once you scuff and clean the panel, DO NOT touch it.
       
    23. MONMIX

      MONMIX I fix dents Staff Member Moderator Elite Explorer

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      paper.jpg
      Tape it up, bag it and roll it into the paint booth. ( you all have a paint booth right ;) )
      Do not use news paper for masking. It is fibrous and the over spray will not always stick to it and
      the air from the paint gun will blow the dried paint back onto your wet paint. Meaning, dirt in your paint.
      I did not paint the truck. The adage is body men can't paint, and painters can not do body work.
      I believe this.
      I also was not there for the paint process so I have no photos.
       
      Last edited: November 7, 2004
    24. MONMIX

      MONMIX I fix dents Staff Member Moderator Elite Explorer

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      painted.jpg
      Here is the fresh painted Ex, unwrapped, untaped, ready to be put back together.
       
    25. MONMIX

      MONMIX I fix dents Staff Member Moderator Elite Explorer

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      finished.jpg
      Give it a bath, to wash off the finger prints.

      I hope you could follow and make sense of all this.

      Different dents in different locations will present numerous challenges and scenarios.
      PM me if you have any questions or need any help.
       
    26. ions

      ions Active Member

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      Damn glen burnie little bastards! i was near the best buy right off richie hwy and some kid through a soda can at my truck and i slammed on my breaks and chased his ass all the way to his house his parents beat the crap outta him and told me if there was any damage to my truck they would pay for it but i was lucky as it left just alittle dint that could be fixed in a day with simple tools and the paint wasn't scratched at all. Sorry to hear about the dent and im glad it didnt get the glass.
       

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