Thread: removal of body filler

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Just wondering the best way to remove the bondo used to fill the body line between the rear fender & quarter panel. I"m thinking a 4" side grinder, I need to take it down to the metal to weld in the fender extensions. This is a continuation of my last post "fender flares?"

Grinding, then wet acetone. Body filler unless it is lead, is polyester resin. Acetone dissolves that.
Unless there is rust pits, though, a grinder should make it all shiney.
Love to see photos of your fender mods when you are done.

i have used a propane torch and wire brush. a couple of passes and it turns to dry powder. less mess than a grinder.

Thanks for the replies. I just took some pics, I"ll try to get them posted tonight.

I like the torch idea. I'll have to try it. In the past, I have noticed areas of bondo will just peel right off near an area where I have welded.

Otherwise: I have always found that a knotted wire wheel makes pretty quick work of bondo removal.

it does'nt take much heat, just a little.

Be carefull with the torch, I've seen a lot of warpage from people using this technique. I like to grind as much as I can and then media blast the last bit to really get the nooks and crany's cleaned out, madia blasting must be done carefully as well to prevent heat build up.

you dont need the heat it's the flame burning off gasses. just dont get carried away. i dont do this anymore since we opened the blasting shop. it's not heat that warps metal in blasting. each sand partical is like a small hammer banging away at it at high pressure. plastic media wont produce any heat to speak of. i use type 5 acrylic and have 185 cfm compressor at 50 lbs or less. we use 3m starblast for rust and clean up.

Originally posted by cartersbs
Be carefull with the torch, I've seen a lot of warpage from people using this technique. I like to grind as much as I can and then media blast the last bit to really get the nooks and crany's cleaned out, madia blasting must be done carefully as well to prevent heat build up.

He won't have to worry about this... All you have to do is pass over the bondo a FEW times and it should start breaking up and getting powdery like shine said. After that, get a scraper and 80 grit sand paper and take the rest off and smooth the metal.

Originally posted by vettedreams
Just wondering the best way to remove the bondo used to fill the body line between the rear fender & quarter panel. I"m thinking a 4" side grinder, I need to take it down to the metal to weld in the fender extensions. This is a continuation of my last post "fender flares?"

a heat gun and a plastic puddy knife will work just fine.

i dont know exactly what happens but just a couple quick passes and it tuns to powder. i use a welding brush to knock it off. it takes quite a bit of heat to start shrinking metal.

Sure do wish you lived a bit closer, Shine. Sounds like and excellent method of blasting you use!!!!! I wrote it all down and will save it for reference when I get my roadster blasted. Thanks for the info!!!!!

it's been a learning exsperence. i researched the blasting bez for about a year before we got into it. i thought i knew what was going on first i found out warpage does not come from heat. i was told walnut shells release some oil when used. not sure about that one but they know more than me. ther are so many blasting matereals it's insane. sand has been out for many years. the acrylic is softer than metal but harder than paint so it shatters the paint off without harming the metal. not sure what starblast is but it works great on rust but does not hurt the finish it's only about 10 bucks a bag. a 50 lb bag is half the size of sand.