BUILD THREAD Project Olds Cool (Recognition!!)

The door looks great, straight as an arrow for sure after all that work.

How do you plan to dig out the key and handle recessed without messing up the surrounding area?
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Donovan You are a great resource to this forum And I have been reading and watching how to videos as you suggested. But still have questions. Can you explain why the need for using putty after filler? Is it just a way to fill in low spots or ?

Tony, polyester finishing putty is a lot thinner and has a lot more runny consistency. It’s also a lot easier to sand than regular body filler because it’s softer. It’s a good idea to use finishing putty on top of regular filler because it will fill in minor deeper sand scratches, pinholes, and level out the surface. Think of it as an “in between” product to use between filler and high build primer.

In a perfect world, with perfect application of regular filler, no deep sand scratches, and no pinholes, it is possible to finish in regular filler, and go straight to epoxy and high build. (I’ve done it before in the past). But that seldom happens, so the extra step of finishing putty is a good idea and added insurance.
 
How do you plan to dig out the key and handle recessed without messing up the surrounding area?

Power tools baby!!

Before I even start filler work, I always make sure to carefully mask off the recesses right on the edges of the transitions.

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I have a selection of single flute, single cut burrs intended for use on aluminum, but they work equally well for this purpose because they don’t clog up:

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I just chuck them up in one of my die grinders and carefully work my way back to an edge.

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Once I’ve worked my way back to and found an edge, I know roughly where the rest has to be brought back to as well. I’ll go ahead and grind out the bulk of the excess, then switch to sandpaper and start following it around from there.

As I get close to the edges with the sandpaper, I can start slowly removing the masking tape, and it gives me a nice clean defined edge. The masking tape definitely helps the process and drastically cuts down on the amount of sanding required. You just gotta make sure you don’t get carried away and start pulling the tape out from under filler that’s still too thick. Or else you run the risk of it chipping back into the filler on the surface.

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I keep on in this manner until the entire perimeter is done, then very carefully and gently transition the filler back into the edges.

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It’s a bit of a process, but it's always been effective for me.

D.
 

Hey, that’s awesome Mike, but you know this ain’t Facebook right? There’s no need to post selfies here for us to know what you look like!
😉😂
 
Lock recess has now been done too. Ready for masking and epoxy once I get my poor shop cleaned up again.

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D, you say the door speaks for itself. It does look beautiful, but I ain't got a clue what it's saying, just like that Russian stripp...... errr, nevermind.

Actually Bruce, what I said was that the floor spoke for itself. It pretty much tells the tale of how my day went on it yesterday. I probably logged in close to 10+ hours on the door yesterday, and it was anything but pretty.
In fact I’m pretty sure I’ve still got dust in areas that it really shouldn’t be.
😮

As for your Russian stripp.... well, what can I say? Some people just bring it upon themselves...
😂😂
 

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