i decide to stip sand the jams in prep for painting. so i did one then wondered what is under that bondo.......

so yes i sanded the bondo off behind door and low and behold this is what i found.

a nice little dent the size of a half dollar and some rust.

i sanded the rust out with a angle die grinder with the 3m wheels. i forget the name of them i will update that later.(rolloc)

i pulled out my 20 dollar body hammer set and tapped the dent out from the inside of the car with a doly on the outside. A little tricky to do with little room but once i got the feel for it just a little tap at a time it came out nicely.

jeff

 

so after i finished up the most of that one i said ..self might as well take the bondo off the door too. as shown in this photo

i sanded that all off and man was it thick i would post pic but would go over limit of 3 pic. so under that one i found te rest of the dent from the back. previous owner must of rubbed something and creased it all the way down 3/4 of the door. the filler was so thick i could put my finger in the spot i ground out and it was close to the outsode body.

i figured cake i can dolly that on out too.......

Nope door support bar going right through the midle of it no way to get at it.

so i drilled a series of holes and used an allen wrench on a pair of vice grips to act as a puller and worked the crease from end to end and back again until it was 90 oercent better. no way to get this on as good as the first. but alot less filler needed now so it was worth it.

Jeff

 

ok so here is the pic of both spots pulled and tapped and sanded out

my next step will be expoxy seal and filer.

i just may be getting the hang of this stuff

Jeff

 

Nice work man! Glad to see people teaching themselves how to do this kinda stuff.

Kat

 

hey, how are you strip sanding, what you using? I'm about to do the same thing. Do I need a carwash first? So i hear...

 

lol I had some bubbling in my paint near the door on the passenger 1/4 panel... and when I sanded it, I found that 90% of my car is made of bondo!

Good luck with it, and let us know how it turns out!

 

Hey Jeff,
The progress is goin' great, Good thing you did decide to go farther.
I would, if you can get your hands no a welder, stitch those holes shut. Youll be back into those doors in a couple years, if you don't.
Maybe you have plans to replace it in a year or so?
At ther very least use duraglass or maybe allmetal, (waterproof)