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DIY: Shaving emblem (using Fiberglass) and treating minor surface rusts

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DIY: Shaving emblem (using Fiberglass) and treating minor surface rusts

Old 02-Sep-2007, 12:24 AM
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DIY: Shaving emblem (using Fiberglass) and treating minor surface rusts

This is a project from ImportCube.com.

I purchased a black trunk from a member here for a very good price. The trunk has a couple of holes for mounting an aftermarket spoiler, and a moderate amount of rust around those mounting holes. There are also a large number of deep scratches and light scratches throughout the surface of the trunk.

I am hoping to refinish this trunk in gloss black, making use of fiberglass and body filler to shave/straighten the trunk back to its original condition.

The best way to shave a trunk is to weld a piece of metal in place. Using body filler or fiberglass to fill the hole is a bad way of shaving a hole because metal and these two products contrast/expand at different rates; hence, the shaved area will crack eventually.

Since I do not have access to a welder, nor do I have any welding experience, I have chosen to go the fiberglass route (a slightly better choice than using only body filler), as I want this to be a managable, and easy to follow DIY project.

This is a picture of the trunk. The emblem has been pulled off here.

This picture shows the rusting spots around the mounting area.

Using 40-grit sandpaper, I hand sanded all the rust away down to clean, silver metal, a requirement to keep rust from coming back to the trunk any time soon. I then feathered the 40-grit area with a 120-grit sandpaper, and throughout the entire trunk to get rid of light scratches.

The holes from the emblem area have been filled with 3 layers of fiberglass from the back, and will be smoothed out using body filler at the top

This picture shows the mounting areas being filled with 3 layers of fiberglass from the back, as well. The excessive glass will be cut away later on with a regular scissor or dremel.

Day 2

After a day of curing out in the hot weather, the fiberglass has harden to the level where hard pressure against the fiberglassed area will not move it or puncture it.

This is when I used very thin layers of body filler and covered the holes I wanted to shave. I sanded the area to be filled with 40-grit sand paper, and then applied very thin layers of body filler at the area, making sure there are minimal pinholes when applying. When the body filler has semi-hardened, I sanded the area with 40-grit, and then feathered the entire area again with 80-grit.

A close-up of the shaved emblem area. In some cases, you can still see where the holes used to be, but they are completely level and flush with the rest of the surface.

A close-up of the holes where the spoiler used to be

An overall picture of the shaved trunk
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Old 13-Sep-2007, 02:06 PM
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excellent, gimme a call when your going to paint it
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