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Old 08-12-2008, 05:22 PM
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Chad300tdt Chad300tdt is offline
Benzless?
 
Join Date: May 2007
Location: North Wales, PA
Posts: 4,001
I thought I'd add some pics and info to help answer some questions I've gotten. I didn't take pics of all the steps like bending the metal and pop riveting or mixing and spreading filler, but this should help a little.

In these repairs I needed to cut and shape 4 pieces of sheet metal.

In all cases except the rail, I glued the metal from the inside and used Bondo filler and spot/glaze putty to fill the remaining void and make it smooth and level with the body lines.

2 were in this area. 1 slightly curved using my leg and hands and fit between the inner support and the existing body metal (at the left of the pic). The other was for the hole near the bumper support. That piece was compound and required a hammer and an anvil to shape. The duck tape was used to keep POR-15 from dripping through and allow it to help shape the repair area.


1 flat piece was along the rail where you see pink peaking through:


The 4th flat piece was here at the window hole above the antenna. Oh yeah, as you can see I actually used JB Weld as body filler before finishing it off with the Bondo products. JB Weld is much more durable than body filler and spot/glaze putty:


I also used POR-15 fiber sheets inside the well to help add strength. You can see the sheet metal between the body metal and the support:


Topcoated:


After Primer:


Closeups after paint:

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Chad
2013 Jeep Unlimited Rubicon
OBK#44
"Pleasure in the job puts perfection in the work." - Aristotle (384-322 B.C.)

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1985 300TD - Red Dragon
1986 300SDL - Coda
1991 - 300TE
1995 - E320
1985 300CD - Gladys
2006 Nissan Pathfinder LE
1998 Acura 3.0 CL

Last edited by Chad300tdt; 08-12-2008 at 05:34 PM.
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