Bodywork Basics

Achieve perfect profiles and lay a flawless foundation for paint

How to properly apply filler.

Body filler is an essential part of achieving perfect paintwork, no matter how good you are at panel-beating and lead-loading. A thin layer of filler allows you to cover up tiny imperfections and create a perfect surface for the paint. If you get it right, you can achieve better panel profiles and surface finishes than when the car left the factory. If you get it wrong or make a slapdash job, however, the paintwork will never look right.

For some, filling is synonymous with bodge-work. Its cheapness and ease of use means that rank amateurs often trowel it onto panels inches thick, finish it poorly and use it to hide a multitude of sins. If it’s correctly and appropriately applied, however, you’ll never know where filler has been used once the paint is in place.

Polyester filler technology has advanced significantly from the fillers used some generations ago. There are many grades, brands and varieties designed specifically for steel, plastics and other surfaces.

Filling and sanding aren’t difficult, but without taking proper care it’ll leave your bodywork looking like a dog’s dinner. It’s a cliché, but the finish truly relies on the preparation beneath. If it’s less than perfect, your expensive paint-job will be for nothing. In fact, the better the quality the paintwork, the more it will show up dodgy preparation.

Achieving excellent results requires patience and a bit of practice. There’s no reason, however, that anyone shouldn’t be able to match – or surpass – professional standards at home. This guide will expedite your progress. We’re working with Chris Spencer of Flat Cap Classic Cars

(flatcapclassiccars.co.uk), who has many years of classic bodywork experience.