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Filler & sanding Part 5 (Shell & panels)

I've received a few questions in regards to what tools I've been using for the panel prep sanding work. 

Air-powered speed file - This is not a cheap item but it does a fantastic job at quickly knocking down the filler using fresh 40 grit sandpaper. It's also not an essential tool however it has saved me a significant amount of time in manual sanding.
Cheese file (half round) - After the body filler is half set you can quickly remove much of the excess height of the filler, and it's also much easier to clean up than the fine dust created when sanding filler.

Hand speed file - Provides finer control over larger flat areas than the air-powered speed file. 

DA air palm sander - Excellent multipurpose sander over various panels and minor contours. This is my go-to tool for removing the gloss from the fresh filler before further sanding.
Dura-blocks (various lengths/profiles) - Used for blocking with anything from 40 grit and finer sandpaper. 

Custom 3D printed sanding blocks for sanding or checking various curved profiles.

Round Durablock sanding block and a few offcuts of various diameter PVC pipe - Used in a few specific areas to sand concave curves. I also used a few random pieces of steel and timber with sharp or slightly rounded edges helped out in specific areas of the body & doors.

This pump up pressure spray bottle is used to quickly spray wax & grease remover just prior to paint. Any bottle like this has to be suitable for solvents such as brake cleaner otherwise the seals get destroyed in very little time.


Back to the sanding...

The entire shell and all panels have now had substantial number of hours spent on filler & sanding to get everything level and smooth (by feel of hand). Everything now needed a final check to resolve any minor low areas before everything was painted with high-build primer. 

Unlike previous iterations of filler and sanding, this time every panel had dry guide coat applied before being blocked with 120 grit sandpaper to reveal any low areas that were not previously obvious to the eye or hand. Any low areas were then skimmed with filler & re-sanded.

Example of dry guide coat applied prior to sanding :

The drivers door had a few small low spots on the edge and corner, indicated by the areas of black guide coat reamaining after sanding.


The passenger door needed a really thin skim across a larger area :

The bonnet and bootlid were good and did not require any further filler. The spots on the bonnet here are small areas of rub through to bare metal, not guide coat indicating low areas.

The roof needed some really thin skims of filler to fix a larger number of low areas.

The shell driver side front & rear needed a few minor fixes :


The passengers side rear had a thin skim over some larger areas :

Engine bay had a few small corrections :

The boot floor had a few skims over most of the area. The boot floor is definitely not perfect but it will be hidden under a liner anyway.

... and rear valance had a couple of minor corrections


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