When I put new rockers/sills/strengtheners/floors/etc in my car, the old
rockers had as much as 1/2" of Bondo in places (Put it this way: I
essentially popped my rocker panels off with a big screwdriver!)
As for how much is too much, I can tell you that this body job was at least
ten years old, and the pieces I took off smelled fresh. In fact, a buddy
came over in mid-process and thought that I'd already started my repairs!
Luke
'71 Spit "Fireball" - in storage for another winter
'73 MGB "FUrniture" - never came out!
'85 Voyager 5-speed "Indestructible Off-Road Winter-Beater"
'01 Toyota Echo "The Big Car"
----- Original Message -----
From: "Mike Ross" <MIKEROSS@Prodigy.net>
To: <spitfires@autox.team.net>
Sent: Monday, October 15, 2001 3:40 PM
Subject: Experience with thick coat of Bondo?
> I was replacing the floor panel on my Mk1 Spitfire when I noticed that
> that the rocker panel and rear wing were over contoured indicating a
> surface filler was used. I had to remove an inner side panel and
> noticed the rocker panel was rusty inside and I could see where
> numerous holes had been drilled to anchor filler. I ground off the
> Bondo and measured it to be 3/16" in some places. I decided it would
> be best to replace the outer rocker panel. After removing it, I
> ground off the paint at the lower front part of the rear wing. Again,
> I ground through excell Bondo up to 1/4" in places.
> The prevous body man had used a ballpean hammer to pound in the metal.
> He then drilled a series of 1/8" holes to anchor the filler. He did a
> pretty decent job for appearance, except for the slight
> overcontouring.
>
> My question: How much filler is too much? I hated to cut away more
> sheet metal, but I kept having dreams of the bondo falling off after
> hitting a bump in the road.
>
> Mike http://pages.prodigy.net/mikeross/
> '66 Spitfire
> '70 GT6+ (maroon)
> '70 GT6+ (green)
> '68 Spitfire (body for GT6 convertible project)
> '69 GT6 parts car (for project)
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