Body prep for paint- stress cracks from body on/off

[mlewis]

Hi all, been working with a local painter (MA) on the final body prep. We’ve had the body on/off for prep and primmer. In taking the body off (carefully- even removing the door hinges to avoid over spreading the body around the rocker panel), we have seen some stress cracks develop in the top of the door lip where the opening meets the cowl.

Here is a picture 188608

Is this typical?

Any way to avoid (other than to paint withe body off) ?

Any suggestions on how to repair to prevent once paint is on the car ?

Thanks, Mark

[Jeff Kleiner]

It’s not unusual BUT IT’S NOT FROM BODY R&R! It’s because in recent years that ‘glass is often thin and many times there is a void under the gelcoat. I bet if you or your painter does some exploring/excavation you’ll find that there is not solid fiberglass under the gelcoat where you see that crack.

Jeff

[mlewis]

Yup, you are right, thin with voids. Any suggestion on how to address?

My body guy used a thick layer fiber reinforced putty filler. Seemed to do the trick for the PS? Not sure if it will hold up long term?

[GoDadGo]

I used Fibertech, which is a reinforced filler, for issues like this on my car.

https://youtu.be/tY3E0ztz8SY

It is a commonly used filler used on Corvettes.

[JimLev]

Both of my A pillars were paper thin and broke thru. I stuffed them with resin coated fiberglass and then used short strand Evercoat.

[mlewis]

Thanks both. Did the repair hold with no cracks post paint and drive ??

[MB750]

This thread makes me want to tap every square inch of my body with a small hammer before starting any work to see if it's solid.

[j.miller]

I have been checking those areas for the past 5 years. They got a little rougher during covid and supply chain problems. If I don't like the thickness, see voids, excessive gelcoat in that area we flip the bodies over, grind the backside and add 7 layers of 8 ounce cloth . ..da Bat