Filling and Painting

Currently, the chemical industry offers a wide range of body filler compounds. However, for this type of work, the best choice is the two-component body filler paste supplied in the body panel repair kit, with the hardener supplied in a separate tube. To obtain a smooth, correctly shaped filled surface, the paste must be applied with a flexible rubber or nylon spreader.

Strictly follow the manufacturer's instructions (failure to do so may result in incomplete curing of the filler). Mix a small amount of filler on a clean wooden board or a sheet of cardboard. Use the hardener sparingly.

Use the spreader to apply the mixed compound to the prepared damaged area of the body panel. To obtain the correct contour of the repaired surface, each spreader stroke must cover the full length of the area being repaired. As soon as the shape of the repaired area approaches the original shape, stop applying filler immediately. As it hardens, the filler will begin to stick to the spreader, forming lumps and leaving grooves in the surface. Continue applying the filler in layers at intervals of approximately 20 minutes until the repaired area is slightly raised above the surrounding undamaged metal of the panel.

After the paste has hardened, remove the excess filler with a scraper or file. Next, begin the sanding and grinding stage. This work is best performed with waterproof sandpaper of uniform grit and strong abrasive adhesion (preferably imported). Begin grinding with coarse No. 40 sandpaper, gradually reducing the grit down to No. 400. To achieve the required flatness of the ground surface, wrap the sandpaper around a block of firm rubber, wood or foam (for convenience, the sandpaper may be glued to the block). During the process, the sandpaper must be regularly and frequently wetted with water. The described procedure allows absolute smoothness of the repaired surface to be achieved at the final grinding stage.

Upon completion of grinding, the treated area must be surrounded by a ring of clean bare metal, ending in a gradually tapering edge of intact paint coating. Rinse the treated area of the panel with clean water to wash off all abrasive residue generated during grinding, then dry the surface thoroughly.

Spray the treated surface with a thin layer of light-colored primer from an aerosol can. This will reveal any errors made during grinding. Detected defects are then corrected by re-applying body filler. Repeat the grinding stage. Continue in the same manner until the required shape and smoothness of the repaired panel area are achieved. Finally, rinse the panel with clean water and dry it.

Now proceed to painting. Work with the spray gun must be carried out in still air, in a dry, warm, dust-free area. If circumstances require painting outdoors, carefully select suitable weather conditions. When working in an enclosed area, suppress dust by wetting the floor with water. If only a separate section of the body is being painted, cover the surrounding undamaged panels with old newspaper, securing them with masking tape. Trim elements such as chrome decorative strips, door handles, headlight bezels, etc., should preferably be removed from the body panel before painting.

When using paints supplied in aerosol cans, shake the can thoroughly, then spray a test surface to practice the painting technique. Apply a heavy coat of primer to the surface being prepared for painting. The required coating thickness must be achieved by applying the paint in several thin coats. Using plenty of water, sand the prepared surface with fine No. 400 sandpaper. Allow the primer to dry completely before applying the topcoat.

Begin applying the topcoat in thin layers to the primed surface. Start painting from the center of the repaired area, moving the aerosol can or spray gun in circular motions, gradually widening the radius of the spiral, and continue until the entire prepared area is covered with fresh paint, overlapping the surrounding area by three to five centimeters. Within 10 to 15 minutes (preferably no later than this, to avoid damaging the edge of the paint that is beginning to dry) after applying the final coat, remove the masking tape and newspaper covering the surrounding body panels.

Full curing of the paint occurs after approximately two weeks. After that, to blend the transition from the fresh paint to the old paint, rub the repaired surface with fine polishing compound. Finally, treat the panel with wax.