Project Facelift

[RobertK]

What my thread said was:

Will bondo hair sand as smooth as regular bondo? The cracks we have to fill are literally only a few mm wide, if that. Plus, some resin from fiber glassing has already filled part of the cracks. Seems bondo would be a better choice for such a small gap.

Also, isn't it more likely that cracks will form where the bondo meets the plastic, rather then across the bondo since it is such a small are to fill? I just don't see how bondo hair would be any better in our application. Not arguing, just trying to learn.

Bondo-Hair will stick to the plastic surface much better since it is basically fiberglass resin, strands of fiberglass, and a little bit of bondo filler mixed together. The first time I filled my bumper cracks I used Bondo, drove my car for a little over a week, and had cracks forming. I sanded it off and replaced with Bondo-Hair and no cracks ever since.

As far as the finish do like what was mentioned before and use regular bondo filler to smooth out the finishing surface. That's how professionals usually use it. I remember that's also how custom car shops build custom door panels. (Stretch Cloth over panel skeleton - Paint w/ Resin, form with Bondo-Hair (short hair), Sand, Smooth out surface with regular Bondo, Sand till smooth, then paint)

Also know that Bondo-Hair sets up harder to sand then regular Bondo so try to start knocking the high spots off it right before it's completely setup.

[Jand3rson]

Dunno - but mine got deleted as well.

I was deleting all the posts that weren't pertinent to what we were talking about, and no offense Dave, but yours was clearly one of them. While I was selecting the ones to delete, I mistakenly checked Andrew's post also. Make sense?

[h0lmes]

Looks sick Josh. I hope to do this to my car someday.

[RobertK]

When do we get to see some more pictures?

[AndrewBird]

We will continue work this weekend. Pics should follow shortly after.

[Jand3rson]

We will continue work this weekend. Pics should follow shortly after.

Yes, and we're also going to be changing course slightly on something. Nothing major, just going about a different method with something. :D

[GaryE30]

I like your attention to detail.

[Jand3rson]

I like your attention to detail.

Thanks, I appreciate the compliment. I love doing things like this, and so does Andrew. We both have a very meticulous nature, so these kinds of projects are right up our alley, and we have a good time working on them.

[e30tom]

Excellent write up guys, this one goes into my "keep" file.

[DanielHStout]

Josh how much did all of the body parts end up costing you if you don't mind me asking? I am really tempted to do this to my eS now.

[StereoInstaller1]

HAHAHA!!!!

PICS OR BAN, FUKKAR!

Luke

[SiGmA_X]

HAHAHA!!!!

PICS OR BAN, FUKKAR!

Luke

Agreed!

[smonkbmw]

did you finish the front already josh?

[Jand3rson]

did you finish the front already josh?

Nothing has been done with the front yet, we're still working on the bumpers and the rear apron. The front won't see any action until we start painting.

We did get most of the front bumper's paint sanded down, there was a spot where the paint/primer was chipping up pretty bad, you can see it in the pics of the 2 bumpers right when I got them. We used an electric sander and feathered the bad spot out, and got it nice and smooth. We'll be filling whatever depression might remain with filling primer, and we also fixed a small spot that was dented in the plastic, we just used a heat gun and lightly tapped it with a hammer, got it popped back out again.

[Jand3rson]

Another big weekend of work on the bumpers and rear apron starts tomorrow, we're going to be plastic-welding the seams of the bumpers and the trim, and getting everything ready for paint. We'll also begin sealing all of the bare metal edges of the rear apron where we made our cuts with self-etching primer, to prevent rust. Should be a very productive weekend, lots of pics soon to come!