• Hi Guest! Being a Paying Supporter is NOT a requirement to participate at BCF. However, subscribing will help ensure we can continue to serve the LBC community for years to come. If you enjoy BCF and find our forum a useful resource...Please consider supporting us by **Upgrading**
    (PS: Subscribers don't see this banner)

Bondo gone wrong

I had some free time last night and today, so I thought I'd tackle one of the rear quarters on the bugeye project. I wish I had taken a few more pictures so that you could see how bad it was.

After I pulled out all the Bondo and mesh I forgot about documenting the process. Instead I just cussed for hours on end. After cutting, bending and pounding out some patch panels. I contorted myself into all the strange positions required to get the panels welded in place. It was warm enough today to roll the car outside for the grinding mess.

Anyway, it is basically done. When I'm ready to do the body work this section should only need a little more grinding and a THIN layer of fiberglass (unlike the gallon the DPO used).


  • 4649-Bondo-love.JPG
    82.2 KB · Views: 97
  • 4650-metalpatch.JPG
    74.8 KB · Views: 92


Great Pumpkin
Country flag
Heh... a gallon of Bondo and an old screen door can go a looong way!!! /bcforum/images/%%GRAEMLIN_URL%%/smirk.gif


Luke Skywalker
Country flag
I would not use fibreglass, as it tends not to bond to steel. Mar-glass might be the way to go if you are that sort of bloke? Drew must love these pictures??
Cheers, David.


Staff member
Country flag
Nice work, Trevor! That's quite the rusty spot. Sure glad I haven't had to tackle anything like that on the Tunebug (thanks, again, David!).


Great Pumpkin
Country flag
Wish I could do that.


Great Pumpkin
Country flag
he said he made them, boy am I impressed.


Senior Member
That's one smooth job. I know that most people don't care for bondo but that looks so smooth that it doesn't look like it would take much. Great job on the panel too. The time spent appears worthwhile.
Trevor Jessie
regularman said:
Well done, Did you buy that piece or make it?

Funny you should ask. I bought the outside panel since it is a compound curve. However, the one I bought was going to need a fair amount of reshaping to even be close. So, I decided to try and make it myself. It has a few more welded seems than the original, but they are butt welds and therefore hard to detect. I'm doing this at my house and I only have a MIG welder so I had to do a quite a bit of grinding.


Hey, when you're done, do you want to spend a little "working vacation" down here in Fl. and do mine /bcforum/images/%%GRAEMLIN_URL%%/grin.gif ?? That looks great!! /bcforum/images/%%GRAEMLIN_URL%%/thumbsup.gif
Trevor Jessie
On another thread, Jeff said he likes to do body work so maybe you should call him. I'm thinking about giving him a call if I find anther gallon of Bondo tucked up in the other side of the car. /bcforum/images/%%GRAEMLIN_URL%%/wink.gif
Trevor Jessie
I forgot to mention... I needed a piece of 18 or 20 gauge steel for part of the inner closing panel. I didn't have any large enough on hand. So I went in the basement to scrounge. I found an old computer case (1990'ish). At first I didn't look at it because most modern computer cases are 24 gauge or so. But I tapped on it on it and it felt solid. Sure enough, it was about 18 gauge. and... the tag on the computer chassis said "Made in the USA". I kind of felt guilty about cutting up.


I did all my sheet metal work at home with one of the cheap flux core mig welders. It was easeir to weld the thicker metal, plus I wanted any patch I put on to lase forever so I made everything out of 11 gauge. cut out and redid the box under the motor (the one that the crank pulley alwasys hits on) it was rusted out. Redid the lower a pillars where the hinges mount, any holes in floor too. Car may be 5 pounds heaver but hopefully what is fixed stays fixed.
Similar threads
Thread starter Title Forum Replies Date
S TR2/3/3A Anyone care to share their bondo applying techniques Triumph 8
UltimateQuestion GT6 Lots of Bondo Triumph 2
D General Tech Bondo Triumph 25
D After bondo??? Spridgets 6
D Keeping Bondo cool - Texas style Spridgets 1
D bondo, bondo, bondo Spridgets 5
T Bondo, where to start Triumph 25
T Skim coat of bondo? Triumph 6
scoutll Anyone notice a Bondo shortage?? Spridgets 11
M Why you don't use bondo over metal Spridgets 23
zimmy Bondo valance to fenders? Spridgets 7
rlandrum TR2/3/3A TR3A Spare Tire Well Bondo-fest Triumph 5
T Can this gas tank be saved? OR - bondo fest! Triumph 18
PATR8 Body Bondo find Triumph 13
Baz Lost my Bondo virginity. Spridgets 12
T Bondo Triumph 4
drooartz Now I know why there was bondo Spridgets 11
jjbunn Puzzled by Bondo MG 20
B What Lurks Beneath the Bondo MG 38
beaulieu best tool to remove old bondo ? Restoration & Tools 14
Popeye Method to remove Bondo Triumph 2
TR4nut Speaking of bondo Triumph 3
Darwin Can you say BONDO??!! Triumph 16
B I've Gone To The Dark Side Austin Healey 18
M TR6 Fresh rebuild gone bad!!!!!!! Triumph 13
3798j Edd China is Gone Other Cars 12
kennypinkerton MGB Are my wheels too far gone? MG 8
tomshobby TR4/4A A time gone by. Triumph 10
W EtypeBrakes--fluid gone???? Jaguar 6
PATR8 Wedge Where have all the Wedge owners gone Triumph 5
Pythias Gone to the Dark Side Spridgets 21
WillR MGB Been gone to long... MG 14
pkmh Distributor rotor gone bad more than once. Austin Healey 5
glemon Off Topic Gone over to the Dark Side? Triumph 11
O HEALEY 100 Head Gasket Gone ? Austin Healey 10
jackq MGB Found MGB roadster with a/c..owner wants it gone MG 0
T Gone fishing for first tooth Triumph 10
B Hello Gents....long time gone...but Im still at it..lol Triumph 1
jlaird After being gone Spridgets 1
Moseso A simple oil change gone South Triumph 16
scoutll Miss Chuff is Gone - A Midget Owner, I am Not Spridgets 16
3798j Photos of Days Gone By Triumph 7
CZ_Dave Ever gone picking? Other Cars 3
E XK 120 gone but not forgotten Jaguar 0
Jeepster Its all gone pear shaped! Austin Healey 8
Sarastro My Sprite is gone... Spridgets 10
I Bugey 948 engine rebuild gone wrong - need help Spridgets 12
abarth69 Gone Red this time Austin Healey 7
PATR8 the VIBRATION IS GONE!!!!! Triumph 4
S TOBs gone wild!! MG 7

Similar threads