Originally Posted by a031363
I have been getting a lot of requests for helping others shave the webbing, smoothing the body, and custom painting the shell. So, I have decided to create this how to thread for all those interested in this process. If you want to see how a finished shell looks, click on the first link in my sig for pics.
If this gets lots of views, maybe Dre or Prairie will sticky it.
Time required: about 30-60 minutes. You can use a sharp knife that you periodically heat-up to slice through the rubber webbing. I used an exacto knife (no heat) to cut the rubber off. Try to get as close to the plastic shell, but don't worry if some rubber remains...you'll take care if it in the next step.
Time required: about 4 days (1 day if you are very experienced with auto body repair, but then you probably wouldn't need these instruction!).
1) Use masking tape to cover all holes on the bottom and the front of the shell. Tape from the inside of the shell so the sticky side of the tape is facing outwards.
2) Use coarse grit (~60-80) sand paper to take off the remaining rubber and roughen up the plastic.
3) Use high grit (~120) sand paper to smooth out the roughness.
4) Apply a thin layer of Bondo brand Glazing and Spot Putty. This comes in a tube - no mixing required. Let dry a few hours. Sand down with 120-150 grit sand paper.
5) Apply another thin layer of Putty, let dry, then sand with 200 grit sand paper.
6) Apply another thin layer of Putty, let dry, then wet sand with 400 grit sand paper.
The "shell" should now be nice and smooth to the touch and to look at. If any imperfections still exist, repeat step 6 until smoothed out.
Time required: 1-3 days, depending if you are applying more than one color.
1) Spray 2 light coats of Krylon Fusion paint to the shell, waiting 20-30 minutes between coats.
2) Wait to dry 1 hour, then wet sand with 400 grit sand paper.
3) Repeat steps 1-2.
4) Spray 4 more coats, let dry overnight.
Skip steps 5-6 if you only want a solid color, then go to step 7.
5) If you want to add stripes or another color, use the blue 14-day painters tape to cover the areas you do not want to get repainted. This tape will make clean lines, but still remove easily, without residue, within a few days of placement.
6) Spray 2-4 thin coats of the new color/stripes. Let dry overnight, then remove tape carefully.
7) Spray 6 thin coats of (any brand) clear coat, allowing to dry between coats per manufacturer's directions.
Supplies and Cost:
Xacto Knife $1
Wet/dry sand paper, assorted grit $4
Sanding Brick (optional) $3
Bondo brand Glazing and Spot Putty $2
Applicator/plastic spatula (or get one from the kitchen) $1
Blue Painter's Tape $2
Krylon Fusion Paint $4 per color
Clear Coat Paint $1
These are the basics and some optional items. Most of you will already have some of these at home...look around and you might be surprised what you find!