How Thick Can Bondo Be? Will Auto Body Filler Crack, Shrink, Fall Out?

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This video may help answer the question, "How Thick Can Bondo or Body Filler be Applied?" Points out that, as long as you've bumped it the best you can and the surface is prepared correctly, filler can be applied to your needs without fear of cracking, shrinking or falling out.
Tools and Materials:
Wax and Grease Remover: Auto Body Master (Auto Value Auto Parts Stores)
Body Hammer: Martin Tools MRT158G General Purpose Pick Hammer with Hickory Handle
Body Filler: Auto Body Master Light Weight Body Filler $20/gal
Cheese Grater: Stanley 21-299 10-Inch Surform Half Round Regular Cut
Air File: Viking V100 w/ 36 grit paper
Medium Length Board: AES 9-1/2" Sanding Board - 6074 w/ 80 grit paper
DA Sander: National Detroit
Primer: Autobody Master Lacquer Primer Surfacer
Spray Gun: Sharpe Finex FX3000 1.8mm tip

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This guy literally has the best auto body channel. Simple easy to understand and to the point, unlike some other much bigger channels

therealtpain

You're the master of putting rumors and myths to rest. "You can't do autobody work with a flux core welder." Busted. "You can't make a lasting rust repair with fiberglass." Busted. "You can't fill a deep dent with bondo." Busted yet again. Keep up the good work and the great videos.

jakeofalltrades

Back in the day, we used a garbage can lid for a mixing palate and a full gallon can of Bondo to fill a smashed in quarter panel (inches thick lol). Still looked good years later until the car was sold...

kq

Watching this I feel confident to continue doing it this way. So many channels seem to make you feel rough for not basically getting the panel perfect before you use bondo.

bossdog

Glad to see you setting a good example by wearing a mask. Most videos show the person welding, grinding, sanding bondo, spray painting sometimes while smoking and drinking. My friend died at 45 because he never wore a mask and believed he was invincible. Never a good idea to breath powdered rust, steel, paint and bondo.

MoeLarryTheCheese

My favorite channel for body repair tips, guidelines and tutorials!!! I’m just over the border in Indiana, but if ever I’m in your neck of the woods, I’d love to stop by!!

MidwestToolReview

I really enjoyed this. I'm fixing up an olb beater. Trying to bring it's beauty back. You just gave me confidence
I like how you keep it real. No b.s.

jason

Good video, Jerry. On my old truck, the paint job was at least 20 years old. After having the body sandblasted, for restoration, I discovered areas that were 1/2” thick of filler. In looking at the truck, you would have never known there was any filler. Like you said, the secret is good metal preparation.👍

ChipsAndSparksGarage

A 73 charger I did a few years ago the filler was 24mm thick on the passenger side and it was like that for 30 years. I ended up replacing the entire passenger side of the car but I was impressed with how well shit that was 1" thick survived.

ojscustoms

I’m in the middle of my first project car and I get so much out of your videos. All the naysayers out there, but you tell how to get it done. Thanks!

kkendall

oh please. You could build a car body out of bondo. When I was a teen I worked in a body shop where we would fix old service trucks. The trucks we bought used, and were sooo dented they were essentially one great big continuous dent after like 20+ years of being beat up on construction sites. We would often drill over a 1, 000 holes to pull the big dents, then everything else was bondo. I frequently had bondo that literally ran from one bumper to the other bumper.

After restoring them (paint, engines, etc), we would put them in to use on a construction company the shop owner ran. so, it was not like they were then lightly used. never seen one inch of bondo fail.

cenccenc

Very nice clear demonstration without expensive tools, etc. Jerry, the Master at work!

williamwest

I like to use long hair fiberglass filler in deep areas to build it up and then scimcoat with regular filler. You have a better chance of the area not cracking with the long hair filler. Everyone has their own way of doing things.

glockman

I think we need some Lakeside edition filler spreaders, Jerry! Thanks for the demo on cleaning them, very helpful.

erichzimmerman

Always informative. I think the old myths about filler come from a time when fillers weren't as good as they are now and people didn't do a proper surface prep.

BruceLyeg