200 Section 2 Nonstructural Repairs
Copyright Goodheart-Willcox Co., Inc.
Areas larger than 6″ (15 mm) in diameter can be ″
initially sanded with 40-grit sandpaper on an air file as
shown in Figure 9-58. The air file will level the filler
much faster than hand sanding. Try to sand the entire
area gradually and evenly. Sand until a featheredge
is made all around the filler. Then switch to 80-grit
sandpaper. At this point, use hand sanding rather than
power sanding because hand sanding is easier to
control. Large areas of filler can be sanded with a yard-
stick instead of a sanding stick. Because the yardstick
is longer, it can span a wider area of filler. It is also flex-
ible, so it can be bent to conform to a medium crown.
After removing the 40-grit scratches with 80-grit paper,
switch to 180-grit sandpaper to remove the 80-grit
scratches. To sand a crowned area around a wheel
opening, use the curved surface of the sanding block
as shown in Figure 9-59.
Sanding a body line in filler is challenging. It can
be difficult to sand a straight line that matches the
undamaged contour of the body line. Any deviation
will be easily visible in the repaired vehicle. One way
to form a body line out of body filler is to use a body
line sander, such as the one shown in Figure 9-60.
A conformable sander is another tool that can
shape body filler. The conformable sander is pressed
into an undamaged portion of the body line. The
thin plastic sheets take on the contour of the body
line. The sandpaper must be carefully applied to the
contour of the sander. A roller tool is used to make
sure that the sandpaper matches the contour of the
sander exactly. The guide is positioned so the sander
can cut the body line in the filler. It is held to the
vehicle with suction cups.
N N N N O O O O T T T T E E E E
The Th e guide’s gu id e s suction su ct io n cups cu ps will w il l adhere ad he re
only to painted surfaces.
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Figure 9-58. A—The air file should span the filler and
be moved up and down. B—Using the edge of the air
file will prevent the file from flattening the crown.
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Figure 9-59. Attaching the sandpaper to the curved
side of the block allows the block to be used to sand
filler on a concave surface.
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Figure 9-60. This sanding tool is moved along the
body filler to shape the body line.
Air file
A
B
Body line sander