Bodywork repairs - filling and respraying
Before using this Section, see the Sections on dent, deep scratch, rust holes and gash repairs.
Many types of bodyfiller are available, but generally speaking those proprietary kits which contain a tin of filler paste and a tube of resin hardener are best for this type of repair. A wide, flexible plastic or nylon applicator will
be found invaluable for imparting a smooth and well contoured finish to the surface of the filler.
Mix up a little filler on a clean piece of card or board - measure the hardener carefully (follow the maker’s instructions on the pack) otherwise the filler will set too rapidly or too slowly. Using the applicator apply the filler
paste to the prepared area; draw the applicator across the surface of the filler to achieve the correct contour and to level the filler surface. As soon as a contour that approximates to the correct one is achieved, stop working the paste - if you carry on too long the paste will become sticky and begin to “pick up” on the applicator.
Continue to add thin layers of filler paste at twenty-minute intervals until the level of the filler is just proud of the surrounding bodywork. Once the filler has hardened, excess can be removed using a metal plane or file. From then
on, progressively finer grades of abrasive paper should be used, starting with a 40 grade production paper and finishing with 400 grade wet-and-dry paper.
Always wrap the abrasive paper around a flat rubber, cork, or wooden block - otherwise the surface of the filler will not be completely flat. During the smoothing of the filler surface the wet-and-dry paper should be periodically rinsed in water.
This will ensure that a very smooth finish is imparted to the filler at the final stage. At this stage the “dent” should be surrounded by a ring of bare metal, which in turn should be encircled by the finely “feathered” edge of the good paintwork. Rinse the repair area with clean water, until all of the dust produced by the rubbing-down operation has gone.
Spray the whole repair area with a light coat of primer - this will show up any imperfections in the surface of the filler. Repair these imperfections with fresh filler paste or bodystopper, and once more smooth the surface with abrasive paper. If bodystopper is used, it can be mixed with cellulose thinners to form a really thin paste which is ideal for filling small holes. Repeat this spray and repair procedure until you are satisfied that the surface of the filler, and the feathered edge of the paintwork are perfect. Clean the repair area with clean water and allow to dry
fully.
The repair area is now ready for final spraying. Paint spraying must be carried out in a warm, dry, windless and dust free atmosphere. This condition can be created artificially if you have access to a large indoor working area, but if you are forced to work in the open, you will have to pick your day very carefully. If you are working indoors, dousing the floor in the work area with water will help to settle the dust which would otherwise be in the atmosphere. If the repair area is confined to one body panel, mask off the surrounding panels; this will help to minimise the effects of a slight mis-match in paint colours. Bodywork fittings (eg chrome strips, door handles etc)
will also need to be masked off. Use genuine masking tape and several thicknesses of newspaper for the masking operations.
Before commencing to spray, agitate the aerosol can thoroughly, then spray a test area (an old tin, or similar) until the technique is mastered. Cover the repair area with a thick coat of primer; the thickness should be built
up using several thin layers of paint rather than one thick one. Using 400 grade wet-anddry paper, rub down the surface of the primer until it is really smooth. While doing this, the work area should be thoroughly doused with
water, and the wet-and-dry paper periodically rinsed in water. Allow to dry before spraying on more paint.
Spray on the top coat, again building up the thickness by using several thin layers of paint. Start spraying in the centre of the repair area and then work outwards, with a side-to-side motion, until the whole repair area and about 2 inches of the surrounding original paintwork is covered. Remove all masking material 10 to 15 minutes after spraying on the final coat of paint.
Allow the new paint at least two weeks to harden, then, using a paintwork renovator or a very fine cutting paste, blend the edges of the paint into the existing paintwork. Finally, apply wax polish.
