 | Home > Maintenance & Modifications > Minor body work repairs - Advice welcome |
 
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| Mike c Member Since: 11 Aug 2017 Location: Maldon, Essex Posts: 928   
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Looks good, I want to remove my Safari RAI too and will have similar holes to deal with!
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3rd May 2020 10:58am |
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| MarcusM Member Since: 29 Jan 2020 Location: Nottingham Posts: 101 
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Great job! Looking at repairing those screw holes too, thanks for sharing your experience Keswick green 2007 Defender 90 TD5
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5th May 2020 12:57pm |
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| Co1 Member Since: 19 Aug 2018 Location: North Yorkshire Posts: 3677  
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Well the wing is done. Looks pretty good, will need a good polish but I made the mother of all f ups when I lost concentration and started a layer of the clear coat on the panel by the air intake. Bit of a bummer but I don’t suppose anyone will notice when it’s covered in mud.
Before:  Click image to enlarge During: Click image to enlarge After: Click image to enlarge The Mother: Click image to enlarge |
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9th May 2020 10:12am |
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| Co1 Member Since: 19 Aug 2018 Location: North Yorkshire Posts: 3677
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So the wing is done. Thanks to Grafty for the advice on the orange peel, worked a treat. Reasonably happy with it, but here are my findings for anyone thinking of doing the same:
1. The actual body repair is pretty straight forward. I’m a fist timer but the wing and window frame are straight, flat and ripple free. You can’t see any evidence so if your on the fence, give it a go. 2. The paint went on well and flat. I built up 5 or 6 coats and it looked very good. Paint was from Paint4U on eBay and the colour match is spot on. 3. The clear coat, AKA the problem child! I used 2K clear coat from Frosts. As soon as it went on it looked orange peely. I had read somewhere that this can be due to not getting enough on, so I proceeded to put on some pretty thick coats. Big mistake. After eventually flatting back and polishing up the orange peel is gone, but if you look closely you will see air bubbles trapped in it where it went on too thick. I should have built up thin layers and flatter back and polished. 4. Always, always , always, start and finish the spray off the panel. The reminder by the intake is enough to ensure I never do this again. 5. It could do with a bit more polishing, but it started to rain. The big question is, will it stay or will I get it done professionally? Well, for now it will stay. I know it’s not perfect, but I did it and it is part of the car now. There are mistakes, but they are my mistakes, no one else to blame. It means more to me than if I had bought a panel and had it professionally done. That might sound odd, but there you go. I’m not saying never, but for now it stays. Thanks to everyone that offered advice and insight. Click image to enlarge Click image to enlarge |
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11th May 2020 3:47pm |
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| Co1 Member Since: 19 Aug 2018 Location: North Yorkshire Posts: 3677
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So we’re a week down the line now and the wing has been playing on my mind. I haven’t been happy with how it looks in certain light so I put my glasses on and had a look. It turns out that there are tiny bubbles in the clear coat.
I spoke to Frost and I have a problem called solvent pop. There are a number of mistakes you can make that causes solvent pop and I made them all! Too hot, too thick, not long enough between paint and clear coat, not long enough between coats. It’s caused when the previous layer hasn’t flashed off fully, the coat might look dry but the solvents are still evaporating and if you over coat while this is happening, the gas gets trapped under the next layer forming bubbles. The purpose of starting this thread was to learn how to do body repairs properly and while I’ve learnt some stuff, I’ve also learned what not to do. I’m not giving up. I’ll sand it all back next week and have another go. |
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16th May 2020 10:37am |
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| Rkcorry Member Since: 23 Jan 2017 Location: Northern Ireland Posts: 226 |
Well done for taking the time to document the repairs, looks spot on, I’d gladly let you loose on my windshield surround which will soon need some attention.
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16th May 2020 7:36pm |
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| DG123 Member Since: 29 Aug 2015 Location: North West Posts: 133 
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Great job. Was that with rattle cans or otherwise what spray gun did you use.? 2012 110 XS SW Orkney Grey
2003 D2 Td5 Black [SOLD] |
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16th May 2020 8:29pm |
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| Co1 Member Since: 19 Aug 2018 Location: North Yorkshire Posts: 3677
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Yep, rattle cans. Paint from paints 4U and clear coat from frosts.
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16th May 2020 8:43pm |
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| grafty99 Member Since: 15 Aug 2012 Location: North Devon Posts: 4785 
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Col, don't sand it all back! All you need to do is key it flat with 800 grit all over.
Then you can start the process again with the colour matched aerosol
The benefit of this is two fold, firstly you get a thicker coating of paint overall on the repair and also if you were to get a stonechip or similar it will be blue underneath 2002 90 Td5 Station Wagon
1990 Vogue SE Triumph Tiger Explorer 1200 Td5 90 Thread http://www.defender2.net/forum/topic50767.html Tdi 110 Thread https://www.defender2.net/forum/topic69562.html RRC Thread http://www.defender2.net/forum/topic54492.html Instagram http://www.instagram.com/george_grafton Last edited by grafty99 on 16th May 2020 9:43pm. Edited 1 time in total |
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16th May 2020 9:03pm |
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| Co1 Member Since: 19 Aug 2018 Location: North Yorkshire Posts: 3677
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Cheers Grafty. Seems ridiculously obvious now you say it!!
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16th May 2020 9:08pm |
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| grafty99 Member Since: 15 Aug 2012 Location: North Devon Posts: 4785
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No worries, it saves time too
2002 90 Td5 Station Wagon
1990 Vogue SE Triumph Tiger Explorer 1200 Td5 90 Thread http://www.defender2.net/forum/topic50767.html Tdi 110 Thread https://www.defender2.net/forum/topic69562.html RRC Thread http://www.defender2.net/forum/topic54492.html Instagram http://www.instagram.com/george_grafton |
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16th May 2020 9:45pm |
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| Pugit666 Member Since: 04 Mar 2020 Location: York Posts: 43 
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Looks like you did a great first timer job, I have a similar thing to do with a small hole under the fuel cap. What did you use to fill the bolt holes?
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18th May 2020 9:48pm |
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| Co1 Member Since: 19 Aug 2018 Location: North Yorkshire Posts: 3677
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I used a fibreglass filler to fill out the bulk of the hole, then sanded back and then used normal filler as a top coat. The holes on the wing were about 11mm so I bonded in an aluminium backing plate first.
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19th May 2020 5:07am |
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| Pugit666 Member Since: 04 Mar 2020 Location: York Posts: 43
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That makes sense , did you use a 2 in 1 epoxy glue to bond the aluminium on? I was thinking of going that way. I was also thinking of filling the bulk of my hole with another piece of aluminium. Mine will be about 50mm square.
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19th May 2020 10:07am |
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