I decided My wife's Golf should be one colour again. I thought I would make a little article on how I did it, for kicks. I would say criticisms and advice are welcome but hey this is the FTL BBS. I'll get em without asking I am sure.
These techniques are not for winning The Riddler but They work good enough to BS most people who don't look too closely. A while back Me and the ball-and-chain got slammed from the side from a little electric car. I have the maintenance book. German cars tend to be easy to take apart as long as you find the little "keys" and the inside door card was easy to remove following the instructions in the book. After accessing the doors inside, I carefully press popped the door back out pushing on the biggest surface I could by cutting little peaces of wood to fit. Basically I set it up carefully and popped it back out in one push. This is the best way to avoid wrinkling and tool marks. On the fender I had a little less luck and had to BS quite a bit with Bondo after I pushed it out a little using the trim mounting holes with bolts and accessing a little with a crowbar from the inside taillight access panel.

The results were thus after a very long break in the action. 2 huge underpaint rust spots appeared. I scraped off the paint and set water based rust eating solution on it overnight. It was pretty badly pitted when most of the rust and old paint was removed.
TIP: Before touching up a cars paint Do not wash it. Just clean the part you are going to work on. Overspray doesn't stick very well to dirt.
TIP: Be patient with the drying of the bondo and paints. It isn't worth it to hurry.


To hide the pitting I used a thin layer of bondo. I use old plastic containers for bondo. I cut out a little applicator to mix the goop and apply it, and a big flat one to use to trawl it off, You shouldn't leave more than you need unless you really like sanding.
Tip: When sanding, Trust the feeling in your fingers to find rough and smooth (you want smooth) you cant really see them.
Tip: Use sandpaper rapped around a small block of wood to smooth it over. Never sand with just your fingers in paper.

Just before painting. Note I screwed up when I repainted the fender. I discovered another rust patch, down low. My original plan was to mask the door by itself and paint it from the trim down, (because this would have been the easiest way to hide the new paint) but I had to redo the other sections.

I am a minimalist with the primer. Both thin and only covering the naked metal. I like to use Rust-Oleum brand primer because, in my experience, it sticks and and can be stuck too very well and it inhibits rust.

I didn't fix the rust pitting in the inside of the door this photo is just to show the difference the bondo process does.

I figure as long as I keep it dirty the repair will pretty much disappear.
