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 Post subject: Body Part Gap Filler?
PostPosted: Mon Mar 11, 2019 6:59 pm 
I am merely driving my van
I am merely driving my van

Joined: Mon Nov 18, 2013 12:50 pm
Posts: 9
Location: Falmouth, Cape Cod, MA, USA
I had an issue where I needed to remove a rear light mount. This is the plastic or composite part that fits into the panel through which the light fixtures are threaded and to which the actual light fixture itelf is mounted with 2 screws. It was steel-pop-riveted in and had some kind of white filler to plug all the gaps between it and the metal body panel to which it was mated. I’ve managed to grind all the rivets off (new tool, a Dewalt angle grinder model DWE4120 - love it!) and clean up all mating edges but want to make sure I use the right stuff to bed the mount to the body panel. The stuff I cleaned out is still actually somewhat non-brittle - amazing after 15 years. It doesn’t seem particularly adhesive, although I did have to use a large flat-bladed screwdriver and mallet to remove a few larger pieces here and there - they just basically popped off with not a lot of resistance. I’ve never worked with Bondo but I suspect maybe this is what was used. Most gaps are a bit less than 1/8th inch but in a couple places there were thicker applications filling gaps in the range of 1/4 to 5/16ths.

Falmouth, Cape Cod, MA, USA

2004 RWD Astro Base (purchased late 2018, 93K miles) (3rd time’s a charm - rustproofing, I promise!)
2000 AWD Safari SLE (purchased 2011; dying of undercarriage rust 143K miles - MY BAD!!! - selling for parts)
1988 AWD Safari (probably SLE?) (purchased very used; replaced engine w/rebuilt; scrapped at 23 years, undercarriage rustout)

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