Automotive body work is something most people would never consider doing on their own. However, most body work is expensive and leaves people driving around with dents or rust rather than having their vehicles repaired. With the right tools and clear instructions, almost anyone can repair the body of their vehicle so that it looks good.
Tools Needed
Almost all of the tools needed for auto body repair and refinishing can be purchased from a local automotive supply store. To begin, you will need an air compressor if you have more than light sanding and spray painting to do. A good air compressor with at least a 5 gallon capacity capable of a minimum of 50 psi is needed, along with an air hose to connect the compressor to the tools. Air tools needed are a grinder, dual action sander, primer spray gun and a paint spray gun.
Hand tools and other materials necessary are a body hammer, drill, slide hammer, long sanding block, sandpaper in various grades, wax and grease remover, auto body filler, masking paper and masking tape.
Repair
To begin repairs, start with the dents. Drill multiple holes in small and large dents on the vehicle. Place the screw tip on the end of the slide hammer into one of the holes and slide the hammer/handle back and forth. This pulls the sheet metal back out and into shape. Rotate using the slide hammer in different holes inside each dent to pull the metal more evenly. It won't ever take perfect shape, but can come close. Use the body hammer to tap down any high areas in the sheet metal.
Grind all of the paint and primer away from inside and around the dents until each dent is nothing but bare metal. On these bare areas, apply a thick coating of auto body filler. Use the supplied plastic squeegee to spread the filler over the dented area. Allow it to dry for an hour. Use a dual-action sander and 80-grit sandpaper to sand the filler until it is smooth and even with the surface of the car. Go over the area again using 120-grit sandpaper to further smooth the area. Use the open tip of the air hose to spray air on the area to clear the dust, or use a towel and the wax and grease remover to wipe the area clean.
Place masking tape and paper on all areas of the car that won't be sprayed with primer or paint. Make sure to cover all window glass, mirrors, trim, wheels, tires, grilles and lights. Spray a light coat of primer over the repaired areas and allow the primer to dry for thirty minutes. Use the long sanding block with 300-grit sandpaper to lightly sand the primer. Hold the block sander level with the surface of the car so you can find any low or high areas in the surface. Low areas stay dark with primer because the flat surface of the sanding block doesn't get into the hole. High areas area quickly sanded down to the metal. Repair these areas with more filler or a body hammer and repeat until the surface is smooth. Wipe the area down with wax and grease remover.
Painting
Painting is best done inside a paint booth. If this is not an option, paint inside a clean garage. Open all doors and windows to vent the area. Always wear a painter's respirator mask while spraying primer or paint.
Wipe the areas to be painted with wax and grease remover several times. Spray three to five thin coats of paint over the areas, waiting at least 15 minutes between each coat. Make sure the coats are thin so they don't cause runs. If the coverage is not dark enough, apply several coats. Once the final coat is applied, wait a few hours before moving on. Spray three to five coats of clear coat paint, waiting 15 minutes between each coat. Make these coats thin also. Once the final coat has been sprayed, pull the masking paper and tape off of the car and allow the car to sit for a full day to dry.
