Repair Large Hole in Car Body

Materials Required

• Fiberglass repair kit
• Sandpaper (80-grit, 120-grit, 220-grit)
• Body filler
• Bondo spreader
• Mixing cups
• Mixing sticks
• Rags
• Rubbing compound

Instructions

Step 1: Clean and Prepare the Area

1. Use sandpaper to remove any rust or debris from the area around the hole.
2. Wipe the area clean with a rag.

Step 2: Cut the Fiberglass Patch

1. Cut a piece of fiberglass mat that is slightly larger than the hole.
2. Use scissors to trim the edges of the fiberglass to fit the hole.

Step 3: Apply the Fiberglass Patch

1. Mix the fiberglass resin and hardener according to the manufacturer’s instructions.
2. Apply a thin layer of resin to the area around the hole.
3. Place the fiberglass patch over the hole and smooth it down with a bondo spreader.
4. Allow the fiberglass to cure for the time specified by the manufacturer.

Step 4: Sand the Fiberglass Patch

1. Once the fiberglass is cured, use sandpaper to sand the patch down until it is flush with the surrounding metal.
2. Start with 80-grit sandpaper and gradually move to finer grits (120-grit, 220-grit) until the patch is smooth.

Step 5: Apply Body Filler

1. Mix the body filler according to the manufacturer’s instructions.
2. Apply a thin layer of body filler over the sanded fiberglass patch.
3. Use a bondo spreader to smooth out the body filler.
4. Allow the body filler to cure for the time specified by the manufacturer.

Step 6: Sand the Body Filler

1. Once the body filler is cured, use sandpaper to sand the patch down until it is flush with the surrounding metal.
2. Start with 120-grit sandpaper and gradually move to finer grits (220-grit) until the patch is smooth.

Step 7: Primer and Paint

1. Apply a coat of primer to the repaired area.
2. Allow the primer to dry.
3. Apply a coat of paint to the repaired area.
4. Allow the paint to dry.

Step 8: Polish the Repaired Area

1. Apply a coat of rubbing compound to the repaired area.
2. Use a rag to polish the repaired area until it is smooth and shiny.

Tips

• If the hole is very large, you may need to use multiple pieces of fiberglass to patch it.
• Be sure to allow the fiberglass and body filler to cure completely before sanding or painting.
• Use a respirator when working with fiberglass and body filler.