The first coat of Bondo can be leveled with a DA sander. Subsequent coats, (and there WILL be subsequent coats), can be leveled with an air file. Final coats need to be done the old fashioned way, by hand with a sanding board long enough to cover the entire area.
When you think you have it level, prime it and apply one or more coats of spot putty. The spot putty will fill minor imperfections and sand scratches. You may have to apply several coats of spot putty, using increasingly finer sand paper.
Then build up several coats of primer and sand again. By the time you're ready for the finish coat, you'll be up to 600 to 1,000 grit paper.
Keep in mind automotive finishes are contrary by nature. They just love to show off sand scratches and imperfections when you thought you had perfection.
It's a painstaking and time-consuming process, but after 30 years of involvement if there are any shortcuts, I've never found them.
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Today's Featured Article - Sunday Drives - by Cowboy. Summer was finally upon us here in Northern Maine. We have two types of industry up here, one being "Forestry" (Wood Products) and the other "Farming" (Potatoes). There is no shortage of farm tractors and equipment around here! I have been restoring old Farm Tractors for the past 6 years, and have found it easier and less expensive to hit all the auctions and purchase whole tractors for parts needed. My wife who works at a local school, and only has weekends and summers off, while on t
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