Basic Bodywork

[skullandbones]

One aspect of the roadster build has been more dreaded than even wiring for me. So when I finally talked myself into it, it was with some trepidation that I actually started the task. Of course, that's not exactly correct. I started it some time ago with the grinding of the panel seams. I found that difficult but rather satisfying after it was done (hated those seams). So yesterday, I began with the first pass with the body filler. Since it has been many years since I have done any bodywork, I plan to do a single layer on every seam, cheese grade it and then work it with 100 grit. The reason is that I need some hands on practise so by the time I get back around to the first work, I will get that comfort level for the more accurate work. I figure I'll do three passes before primer. So far my biggest issues have been how quick the filler "kicks off". Arizona is not the best place for this but I am adjusting my work time and technique to help mitigate those issues.

So I know there are different levels of expertise and philosophies. I'm trying to keep this as simple as possible. So how basic have people gone with this? I don't plan on blocking the whole car but will spend the necessary time to produce a decent paint job. I have already found one corner on the trunk and some areas around the doors that may require some "bodywork" but the hood looks like it might not require much. I think I will end up spending more time on the seams, body edges (e.g. radiusing the wheels), and trunk, door, and hood spacing than all the rest. I guess that's why it's such a sizable portion of the budget when it's sub contracted. The cool thing though, is that it feels good to have your hands on all those cool curves. It's not so bad after I got started.

I had a friend to come over this afternoon and offered me use of his inline sander. I told him I would try on one area in particular just to see if I like it. I will get one if it is useful. So far I have a gallon of filler, a plastic paddle, a rubber one, a pool noodle, a flexible french curve, and sand paper. I might employ my oribtal hand sander at some point but I want to see how the hand work goes first. I'm using very thin applications so far when you consider how much ends up on the ground after the cheese grater gets done. I'm looking forward to seeing a bunch of fair curves in the near future!! Thanks, WEK. :cool:

[Jeff Kleiner]

You may have found them already but if not you might find some useful information or just a confidence boost by reading through these:

http://www.ffcars.com/forums/17-factory-five-roadsters/266792-mk4-bodywork-thread.html

http://www.ffcars.com/forums/17-factory-five-roadsters/230701-started-body-work-6583-a.html

http://www.ffcars.com/forums/17-factory-five-roadsters/245817-yet-another-bodywork-thread-scott-l-sands-sands-sands-some-more.html

http://www.ffcars.com/forums/33-ask-street-rod-painter/183106-body-work-progress-photos.html

RE: the inline sander and other power tools---after knocking down the mold flash from parting lines and the wheelwell excess I put the power tools away and do it all by hand until it's time to break out the buffer following paint. I know you said that you don't intend on blocking the entire car but I recommend that you reconsider and go over the body with a long board before getting too carried away. The sides, doors and hood are pretty wavy and blocking will take a good bit of that out as well as make visible what it doesn't.

Good luck!

Jeff

[Jeff Kleiner]

You may have found them already but if not you might find some useful information or just a confidence boost by reading through these:

http://www.ffcars.com/forums/17-factory-five-roadsters/266792-mk4-bodywork-thread.html

http://www.ffcars.com/forums/17-factory-five-roadsters/230701-started-body-work-6583-a.html

http://www.ffcars.com/forums/17-factory-five-roadsters/245817-yet-another-bodywork-thread-scott-l-sands-sands-sands-some-more.html

http://www.ffcars.com/forums/33-ask-street-rod-painter/183106-body-work-progress-photos.html

RE: the inline sander and other power tools---after knocking down the mold flash from parting lines and the wheelwell excess I put the power tools away and do it all by hand until it's time to break out the buffer following paint. I know you said that you don't intend on blocking the entire car but I recommend that you reconsider and go over the body with a long board before getting too carried away. The sides, doors and hood are pretty wavy and blocking will take a good bit of that out as well as make visible what it doesn't.

Good luck!

Jeff

[skullandbones]

I think it's funny that there is some variation in the product even amoung the MKIII bodies. I don't know if I got one that was cleaner out of the mold or what but it doesn't seem that bad. When I look at the pics from Jeff's MKIII and the MKIV, mine looks like it might fall between there regarding bodywork issues. But I do remember how bad one wheel well was left unfinished at the factory. I had to spent all morning and three different tools to get it to the point I could radius the wheel area. I guess FFR has reigned in the problem areas on the new model.

Jeff, I am going ahead at a steady pace but I will consider your suggestions as I go forward. I found right off the bat that this is not a power tool friendly process. So I appreciate the validation when you said you put down the power tools until after paint. That shows, at least, I'm on the right track. One thing I am discovering as I do each succeeding session of body filler: the better you smear the stuff on the less work you make for yourself. So I am focusing on getting it on as smooth as possible. I'm employing a flexible tool that I am fairing the curve on the smeared filler similar to the "hack saw blade" trick and straight edge that some other fellows on FFR cars used. It is also good to read the curve after working it to see further low or flat spots on the curve. I find this helpful because the curves are constantly changing as you move along the fender. Now that I have sort of a baseline after my first pass with body filler to bridge the void between the two body panels, it is dialing into what will be the real final curve. As you are doing this process of fill, grate, sand,.........repeat, it gives you time to think about the more challenging parts like matching up the doors, trunk, and hood! Thanks, WEK

[skullandbones]

I have thought about this a lot but there is no substitute for doing in some cases. I found myself scratching my head about my first pass with the body filler on the roadster. I was expecting rather dismal results. That was the surprise. I did not expect it to look so different but it did. Maybe others just see it as the next step in the process but I couldn't get over how good it looked (relatively speaking) to the gel coat and raw seams even after flattening them out. So much so, I primed the areas and stood back and observed. So once again I changed my thoughts on the subject and decided to leave it as is and go on to the insulation, etc. The curves of the body are intact now and even though I understand there will be at least two more passes of filler to get to a the real smoothing stage, it doesn't bother me. I will be driving it like this for a few months (I will sand and prime for uniformity) until all the bugs are out and I have my portable paint booth figured. Can wait to break out all the paint heads I have. Some I've used a few times but most are new in the box.

I'd like to jump forward to when I do start on the perfecting the curves and ask if those of you who have done it: do you have any advice on getting that great finish. I am going to use different color catalyst to very the layers a little. I did use the flexible curve tool to help smooth the inital application of filler. On one side it worked to perfection. I only grated a small amount off. On other areas it didn't work as well but I think that was my fault for not adjusting the hardener with the conditions (It likes cool and no sun). So the weather is cooperating so far.

I think this may be bleeding over into blog territory so I will see about changing the format but I would like your hands on advice, if you don't mind.

Thank you,

WEK. :)

[riptide motorsport]

Looks very nice...good work.