A small area in the rear quarter panel of my wife's car was perforated from rust. I cleaned the area using a Nyalox abrasive impregnated nylon bristle brush (Photo 1) to remove as much corrosion as possible-including the back of the repair area.
To quickly make a backer for the hole, I used G/5 Five-Minute Adhesive. I impregnated a small piece of 6 oz fiberglass cloth with G/5 and spread it flat on a piece of Melamine board. After about five minutes, the cured backer peeled from the surface of the Melamine. I trimmed it slightly larger than the hole in the fender and inserted a screw in middle of the backer so I could pull it into place when I installed it. I then coated the inside edges of the hole with a mixture of
WEST SYSTEM® 105/205 epoxy thickened with 410 Microlight (Photo 2) and flexed the backer slightly to fit it through the hole. I pulled the backer into the thickened mixture, which held it until the epoxy cured. With the backer in position, I removed the screw and completed my repair. I roughened the surface with 80-grit sandpaper and applied a layer of 105/205 thickened to a peanut butter consistency with 410 (Photo 3). I rough shaped this layer after it cured and then applied a thinner coat of the same material. After this was cured and perfectly faired, I coated the entire repair area with unthickened
WEST SYSTEM epoxy and wet sanded. Finally, I applied primer and spray paint using a Preval sprayer (Photo 4).
Sources: Nyalox abrasive impregnated nylon bristle brushes, Dico Products Corp., Utica, NY 13503
(purchased at The Home Depot).
Epoxyworks 17 / Spring 2001
Copyright © 2002, Gougeon Brothers, Inc. All rights reserved.
Reproduction in any form, in whole or in part, is expressly forbidden without the consent of the publisher. EPOXYWORKS, Gougeon Brothers, WEST SYSTEM, Episize, Scarffer and Microlight as used throughout this publication, are trademarks of Gougeon Brothers, Inc., Bay City, Michigan, USA.