how would you fix this chunk??

vader1979

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This is the worst part of my star wars machine....everything else cosmetic is very small. but since this gouge is right on top and right down to the 90 degree corner...how do you bondo and keep that straight angle? i was thinking of using a wood paint stick and tape to the inside...but i am afraid that the bondo will adhere to that stick and then it will be stuck. any advice would be great. thanks!!
 

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Find a cardboard box that is printed (has a smooth, glossy finish - like a diaper box or an old HP printer box, not a plain brown box) and cut a few strips from it, and use these strips as "forms" to do like you described with the paint stick. The bondo will release easily from the smooth coating on the cardboard. Are you planning on re-cutting the tmolding slot?
 
yes...i will have to recut the t molding groove. i have a keyhole saw that is the perfect size thickness for the groove...so very simple. thanks for the tip!



Find a cardboard box that is printed (has a smooth, glossy finish - like a diaper box or an old HP printer box, not a plain brown box) and cut a few strips from it, and use these strips as "forms" to do like you described with the paint stick. The bondo will release easily from the smooth coating on the cardboard. Are you planning on re-cutting the tmolding slot?
 
Bondo would be fine- It's not as bad as it looks.
If you want a little extra "umph", use Bondo fiberglass/ resin.
That stuff is hard as diamonds.
 
"short strand" body filler, bondo makes a version of it.. I use "duraglass" its a fiberglass body filler.. really tough, cant break it by hand. Only problem is, its a nightmare to sand..
 
donkey kong cab

i had this same issue with my vs.super mario bros,i had cut it square with a circular saw (very carefully).and fitted a piece of plywood there and glued it and then sanded,then i cut the grove with a dremel using the cutting wheel,but know i use a rotozip.
 
Think that's the way im gonna go....that and the coated cardboard...




QUOTE=Jedidentist;1986176]Just use regular Bondo, build it up slightly larger and just sand it down.[/QUOTE]
 
You can also get a something the same width or close to the t-molding slot..cardboard with shiny edge works and insert that into the slot so when you bondo you essentially have your t-moldings slot still intact...if you have to cut it out sometimes the bondo can chip and crack..

Just cut a piece of cardboard larger than the area your filling(Length and height wise) in so you have a good fit and it will stay in place..make sure its taller than cab too so you can fill above your hole but still pull out the cardboard when its time to sand and not fill t-molding gap with bondo.

I've used this method and it always works very well..
 
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