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Old 02-17-2013, 08:48 PM   #1
mrchyes
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Default STi Trunk, The Plan

Yes i know this has probably been covered before!

I just wanted to make an up to date thread about how to successfully fill holes in the trunk lid after removing the wing.

The Plan:

3M Bondo body filler - 6oz.
Bondo spreader
.063 aluminum
loctite PL premium poly adhesive

I plan to cut the aluminum into over sized squares on the underside of the trunk and apply loctite adhesive to seal the holes (and hopefully help the bondo not to crack)
then I will fill most of the hole on the upper side with the adhesive
after that I will apply bondo and attempt to make it a smooth transition across the trunk lid.

i will then wet sand, prime, and paint, then clear.

I'd like to know what you guys think about this plan, i'm not dead set on anything, but i dont have the funds to have a professional do it (and id like to learn) and i dont have the tools (welder) to weld the holes.

Let me know what you think!

once I get the supplies I will start in and update with pictures!
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Old 02-17-2013, 08:51 PM   #2
BIGJBEARS
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Buy a welder it will pay itself off a million times over
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Old 02-17-2013, 08:54 PM   #3
mrchyes
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how am I to learn how to use it?
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Old 02-17-2013, 09:11 PM   #4
rs_sedan
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Quote:
Originally Posted by mrchyes View Post
how am I to learn how to use it?
Grab junk steel and start practicing, just dont buy a harbor freight flux core pos, youll regret it later...
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Old 02-17-2013, 09:14 PM   #5
mrchyes
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ill think about it..

might just try fiberglass for now
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Old 02-17-2013, 09:19 PM   #6
rs_sedan
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Quote:
Originally Posted by mrchyes View Post
ill think about it..

might just try fiberglass for now

If you dont wanna spring for a welder im sure you orginal plan would work... That essentially what you would do if you had a welder anyway, well atleast what id do. Cut small pieces of sheetmetal and tack them in from below, the smooth with bondo (i prefer z-glass) and paint.
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Old 02-17-2013, 09:21 PM   #7
mrchyes
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cool, thanks for the help!
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Old 02-17-2013, 09:56 PM   #8
p951951951t
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Make sure you don't get any bubbles in there. I usually like to let stuff get warm/hot (then let it cool) before I paint it just to make sure all the gasses have expanded and escaped from inside the filler. You don't want to end up with bubbling paint the first time it gets really hot in the sun!

I've mostly only had that issue when using plastic welding filler when shaving holes on urethane parts though.
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Old 02-17-2013, 10:03 PM   #9
mrchyes
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i will try and make certain there arent bubbles!
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Old 02-18-2013, 11:29 AM   #10
mrchyes
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The plan as of now:

take trunk off car
cut .063 aluminum into squares and press them into place with loctite PL premium poly adhesive
once adhesive has cured (24hrs) completely cover inside of trunk lid (plastic, tape, ect)
strip paint off trunk lid (just outside)
apply bondo over holes lightly (4-5 coats)
sand inbetween coats (probably 500-750 grit??)
sand down entire trunk (500, 750, then 1200 grit??)
Prime
Paint
Clear
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Old 02-28-2013, 01:59 AM   #11
88hatchback
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you can sand your rough shaping bondo with a 80-120 -220 grit paper.

when it comes to priming - sand the whole trunk with a 220 grit, make sure you use a high build primer (fills scratch marks well)

wet sand with a 600 grit paper (the primer) MAKE SURE YOU USE A SANDING PAD!!!

spray your base coat - make sure you give it lots of time between coats if you're using a water based paint.

First coat is a dust coat - 50% overlap
second coat is a med application with 35% overlap
third is another med coat with 30% overlap to fill all the color in.

if you're spraying clear as well - you can lay it on 1-2 hours after base (with water based)

if you lay on 3-5 coats of clear it'll give you enough paint depth for wet sanding (1000-1500) then cut and polish (buff)


just make sure you watch your edges when sanding - as its easy to cut through the paint and would cause you to have to redo the whole job again.
C.
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Old 02-28-2013, 10:11 AM   #12
mrchyes
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If i do paint it myself i dont think ill wetsand after the clear coat.

thanks for all the info though!
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Old 03-03-2013, 01:12 PM   #13
04wrxhart
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You could also take it to a muffler shop and have them weld the holes shut. Theres a shop by my house and im pretty positive the guy wouldnt charge me more than $20.
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Old 03-03-2013, 06:53 PM   #14
mrchyes
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scratch this whole plan.

i traded for a wrx wing and trunk
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