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2005 Ford Focus ZX4
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<blockquote data-quote="just call me KeV" data-source="post: 8800808" data-attributes="member: 656095"><p>Last post for tonight. The Bacardi has taken hold and Kev is getting sleepy. Part of building panels like this is getting them to have a smoother look by adding body filler to them to match them to the contours of the door panel. In a perfect world the panels would be flat like an old truck but what's the fun in that. You don't want to add tons of body filler to a panel. There can be issues with heat. Tons of layers which means length of time to finish the panel. Not to mention that this **** can get super expensive esp. if your a baller and you are using products like upol.</p><p>So I got the idea to build up the panels with small bits of wood, then you can cover the outside wth filler. Thanks goes out to Peter from PSSounds for the idea.</p><p></p><p>A few of things that you will need.</p><p>1. Glue gun. 20 watts is more than enough for a project like this.</p><p>2. Glue sticks. It's like a fire in the woods. You'll need more than you think.</p><p>3. Wooden dowels. You can decide on this based on the project you are working on.</p><p>4. Coping/jigsaw to cut the pieces to fit.</p><p>5. KItty hair. This is slang for short strand reinforced fiber fill. You get the long stand and you will be having hand cramps. The good stuff can be both drilled and tapped but I wouldn't use more than 30 in. lbs. of torque.</p><p>6. Finally, the lightweight body filler (bondo, slang) of your choice. Use a good one or you will get small holes and pits. Which are a huge pain in the ass.</p><p>7. Plastic spreader/mixer. they usually come in packs of three.</p><p>8. Quality painters tape.</p><p></p><p>[ATTACH=full]40611[/ATTACH]</p><p>[ATTACH=full]40612[/ATTACH][ATTACH=full]40613[/ATTACH]</p><p></p><p>You can see from the follwing photos we are building up the panel to strengthen the panel. Its similar to rebar in concrete. When the kitty hair is added it will fill in all the gaps. A smaller second layer will be added to build the final contour then the body filler will be added at the end to finish cosmetic touches. Keep in mind were are a few steps away from the pretty stage. Any of these can be knocked down after you apply the first layer of kitty hair. I like to use a rasp, hand sand, and an orbital.</p><p>[ATTACH=full]40614[/ATTACH][ATTACH=full]40615[/ATTACH][ATTACH=full]40616[/ATTACH][ATTACH=full]40617[/ATTACH]</p><p>You can see there needs to be a little more glue applied. </p><p>Once the first layer of reinforced filler is applied on the outside we can apply a layer of milkshake. (resin/bodyfiller mix with catalyst) to the interior surface to further strengthen the panels. I've never been proficient enough to build super pretty but mine are always bulletproof.</p><p>After that is all completed I will cover in the suede that I purchased which will match both the front doors and the IB for the 18's</p><p>[ATTACH=full]40618[/ATTACH]</p><p></p><p>More in a couple days...</p></blockquote><p></p>
[QUOTE="just call me KeV, post: 8800808, member: 656095"] Last post for tonight. The Bacardi has taken hold and Kev is getting sleepy. Part of building panels like this is getting them to have a smoother look by adding body filler to them to match them to the contours of the door panel. In a perfect world the panels would be flat like an old truck but what's the fun in that. You don't want to add tons of body filler to a panel. There can be issues with heat. Tons of layers which means length of time to finish the panel. Not to mention that this **** can get super expensive esp. if your a baller and you are using products like upol. So I got the idea to build up the panels with small bits of wood, then you can cover the outside wth filler. Thanks goes out to Peter from PSSounds for the idea. A few of things that you will need. 1. Glue gun. 20 watts is more than enough for a project like this. 2. Glue sticks. It's like a fire in the woods. You'll need more than you think. 3. Wooden dowels. You can decide on this based on the project you are working on. 4. Coping/jigsaw to cut the pieces to fit. 5. KItty hair. This is slang for short strand reinforced fiber fill. You get the long stand and you will be having hand cramps. The good stuff can be both drilled and tapped but I wouldn't use more than 30 in. lbs. of torque. 6. Finally, the lightweight body filler (bondo, slang) of your choice. Use a good one or you will get small holes and pits. Which are a huge pain in the ass. 7. Plastic spreader/mixer. they usually come in packs of three. 8. Quality painters tape. [ATTACH type="full" alt="20220725_212229.jpg"]40611[/ATTACH] [ATTACH type="full" alt="20220725_212302.jpg"]40612[/ATTACH][ATTACH type="full" alt="20220725_212337.jpg"]40613[/ATTACH] You can see from the follwing photos we are building up the panel to strengthen the panel. Its similar to rebar in concrete. When the kitty hair is added it will fill in all the gaps. A smaller second layer will be added to build the final contour then the body filler will be added at the end to finish cosmetic touches. Keep in mind were are a few steps away from the pretty stage. Any of these can be knocked down after you apply the first layer of kitty hair. I like to use a rasp, hand sand, and an orbital. [ATTACH type="full" alt="20220725_212356.jpg"]40614[/ATTACH][ATTACH type="full" alt="20220725_212446.jpg"]40615[/ATTACH][ATTACH type="full" alt="20220725_214040.jpg"]40616[/ATTACH][ATTACH type="full" alt="20220725_214206.jpg"]40617[/ATTACH] You can see there needs to be a little more glue applied. Once the first layer of reinforced filler is applied on the outside we can apply a layer of milkshake. (resin/bodyfiller mix with catalyst) to the interior surface to further strengthen the panels. I've never been proficient enough to build super pretty but mine are always bulletproof. After that is all completed I will cover in the suede that I purchased which will match both the front doors and the IB for the 18's [ATTACH type="full" alt="20220725_214543.jpg"]40618[/ATTACH] More in a couple days... [/QUOTE]
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