While the chassis was gone on its welding and powdercoating improvement journey, the egg was “up on blocks”, and its time for the body work.
We went out to get our supplies, and learning from the last stage, to do preliminary research on the cost of painting the egg after it was all prepared. Insert parade of idiots and outrageous quotes here, and cut to a couple beneficent guys standing in stores with us giving us crucial instructions, and one angel of a guy at a body shop who broke down every stage of what we needed to do.
We had to clean it all with a scotchbrite pad and comet. Giving it this “mechanical scratch” is enough for the paint to bond. For our repair patches, we had to build up the bondo and sand it down, sanding and refining with a primer/filler, arriving at a grit of 4-600! That sounded insanely fine to me, coming from woodworking, but for automotive finishes, 400 grit is not fine enough.
Fiberglass is an unusual animal, and it turns out it’s not very well liked in the automotive world. Too finicky. It shrinks and holds paint differently, and it doesn’t bond with bondo (automotive filler) that same way. Over the fiber, there’s a gel coat that ages with exposure and gets dull, like old boats do. He suggested that we could dispense with painting it and just restore the original surface by buffing out the gel coat. “To preserve the original colours because they were so nice?” I asked. No way was I doing all that work for 1970’s orange.