Prior to applying the underbody coating I 3D printed a heap of plugs in various sizes and inserted them into any nuts/rivnuts to stop the underbody coating from getting into the nut threads. All other openings in the underbody and engine bay were simply taped over with masking tape. The rest of the shell was also masked off with paper & plastic sheet. Note the two mating surfaces for the steering rack was masked off too. Underbody coating is a messy job so the floor was covered in old bed sheets and I wore a full body coverall, nitrile gloves and safety glasses. It was applied to floorpan & inner wheel guards & boot floor with a schutz spray gun. After the underbody coating was completed, everything was painted with 2 coats of satin black. At the same time I painted fuel line/battery line underbody covers with the coating. The middle area of the lower firewall had been masked off as it will be painted in the body colour. The black underbody coating seen here on the firewa
The next task was to apply seam sealer and paint the underbody. I scuffed all areas with a maroon Scotch-brite pad (3M 7447) to prep for the underbody coating and after wiping over everything with wax & grease remover, the seam sealer (Sikaflex 227) was applied to all areas of the underbody and lower engine bay where any panels overlap or had welded rust repairs. Although it looks a bit messy it will all be painted over. I also applied seam sealer in any gaps in the body-sill seam (at the base of the doors/side panels) of which any excess was wiped off with a rag soaked in thinners. Once all the seam sealer was cured, epoxy primer was painted over it. Every other panel join inside and outside of the car as well as boot-lid, doors and bonnet then had seam sealer applied (after scuffing with Scotch-brite pad) Boot : The panel joins in the engine bay and front bumper area had seam sealer applied and any excess carefully wiped off, leaving only the seam sealer at the panel joins : For