Whether you have the knowledge and experience to perform bodywork or you simply want to learn as you go, you'll definitely need the right tools. If you plan to have a body shop complete the work, knowing they have the proper equipment is a step in the right direction when it comes to picking a shop. The basic body shop tools are fairly minimal as you can get away with a sanding block, some sandpaper, and cheap paint, but like anything else, the sky's the limit if you want to fill your shop with specialized tools to make the job easier. The bottom line, however, is time. If you don't have the best tools, you'll spend more time to accomplish a certain task; with better tools, less time is required. Regardless of tools, however, bodywork is labor intensive, frustrating, and trying to hurry only makes it worse. So if you're going to do it yourself, you'll want to give yourself a realistic timeframe, and you'll need to invest in at least some of the equipment we'll discuss in this article.
After welding, an electric...
After welding, an electric or pneumatic grinder can be used to grind the welds flush; the metal can now be treated and is ready for filler.
Anytime a car's body is stripped...
Anytime a car's body is stripped to bare metal, the metal should be treated with OSPHO or another agent with phosphoric acid as the main ingredient. This will chemically neutralize any surface rust and etch the metal in preparation for primer and body filler.
While a little pricey for...
While a little pricey for the novice sheetmetal fabricator, an English Wheel (like this one by Sharpe)...
...and a Power Hammer (like...
...and a Power Hammer (like the one shown by Dake) can be used to fabricate patch panels that aren't available from the aftermarket.
Getting it StraightAfter the...
Getting it StraightAfter the new sheetmetal is bolted or welded in place, it's time to start straightening panels. This process is actually started by shaping and straightening the metal panels themselves so less filler will be needed. Then body filler can be applied and the process of filling, sanding, priming, and sanding again can begin. This procedure is repeated until the panel is straight and ready for final prep and paint.
By using a body hammer (outside)...
By using a body hammer (outside) and metal dolly (inside the quarter), minor imperfections can be removed from the metal body panels prior to adding filler. Hammer and dolly sets are available from most tool stores and are relatively inexpensive.
Applying body filler to panels...
Applying body filler to panels isn't rocket science, and the tools you'll need are as simple as a squeegee and a piece of cardboard or plastic to mix the two-part body filler on.
Once the filler has cured,...
Once the filler has cured, an air-file can be used to knock down the high spots of excess body filler. While the pneumatic file saves time, manual files (commonly known as "bondo" files) are also available to perform this task, and they're a lot cheaper.
If there's one tool you'll...
If there's one tool you'll want to purchase to help with bodywork, it's an orbital sander such as the Snap-On unit shown here. A power sander like this will save you the labor of hand-sanding body filler and primer, and the random orbital action will help keep panels straight and free from imperfections that can be caused by hand-sanding.
Eventually, the panel will...
Eventually, the panel will need to be block-sanded by hand. Be sure to use a foam sanding block for this procedure as sanding without one will leave indentions from your fingers pressing the sandpaper into the panel. Sanding blocks are cheap and available from any tool supply or home improvement store.
To get panels straight, a...
To get panels straight, a dry guidecoat should be applied. This dark colored material marks the panel, and as the panel is sanded the guidecoat remains in the low spots. The same result can be achieved by "misting" the panel with black spray paint, then sanding to reveal low spots. High spots are indicated by sanding through to bare metal.
This panel has been guidecoated...
This panel has been guidecoated and then block-sanded. The low spots are clearly indicated by the dark colored guidecoat remaining on the panel.
Straightening the panels is...
Straightening the panels is the most time consuming part of performing body work. Each panel is block-sanded, filled, sanded again, coated with guidecoat, and sanded again. The process is repeated until the panel is straight enough for final prep and paint.