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Author Boot smoothing guide!... (PICS)
CRB 553
Member

Registered: 5th Apr 02
Location: NE Drives: Punto GT
User status: Offline
   23rd Nov 03 at 22:09   View User's Profile U2U Member Reply With Quote

Just a couple of pics to show you what i did

The lock and wiper have been removed, i did not smooth the number plate recess. (did not want to move the no. plate to reiger, or have to move the plate light) so please dont say smooth the plate recess coz am happy the way it is.

This is just a brief guide for people who want to have a go themselves like me. I dont like taking car to bodyshop, if u do the work urself it feels much better at the end of the day. And its not too hard if u take ur time......

Guide:

First of all, the wiper arm and boot lock need to be removed.
The wiper arm is held on by 1 bolt.
Remove this and pull the wiper arm off, then remove the boot lid card on the inside of the boot so you can see the motor.
Undo all the necessary fixings holding the motor and lock in place and remove them.





As you can see below there is 1 small hole to be filled and one small recess.
Remove any rust with a dremel, and then key into the metal surrounding recess and small hole as shown.
You should remove all of the paint in the surrounding area and score the surface.
This gives the fibreglass something to grip to.





You will now need some P40 fibreglass, which you can get from Halfords.
Cut a piece of metal mesh to size so it fits into the triangle recess in the centre.
This takes up some of the depth and strengthens the fibreglass. (You can weld a small metal plate into the triangle, but its not necessary)
Apply your P40 / hardener mix to the mesh and surrounding area in generous amounts so it contacts all of the exposed metal.
Add some from the back of the boot lid aswell for strength.





Build p40 as shown and smooth it out right up to the edge of the exposed metal.
Dont build outwards too much or it will mean lots of sanding work later on.
Cut out a small square bit of mesh bigger than the small wiper arm hole and stick this on the other side of the hole (inside the boot lid) with P40. Completely cover it in P40 to ensure it holds.
Fill in the small circular recess with P40 as shown and let it harden.





Cut into the metal as shown to make a zig-zag pattern around the recess Do this for the larger one aswell, dont be scared to really cut into the bodywork.
If you leave it smooth the p40 will pop out as a plug.
Score the surface of the P40 aswell so the filler you add next is not griping to a smooth surface.

!This is the most important section, make sure u have rough edges, very important!





Add P38 bodyfiller (Halfords) in reasonably large amounts, pressing it into the boot firmly as it begins to thicken to remove any air bubbles.
Leave to harden

Sanding will take some time so you may want to use an orbital sander / B&D Mouse etc to remove the excess.
Use this until you get to about 2mm of the finishing point.
Now you will need a rubber sanding block (halfords)
You should not use your hand for the final stages or the finish will not be flat.
Use a relatively low grit (400) until the filler is nearly flush with the metal and the paint starts to rub.
Then use a high grit wet and dry (1200)
Rub sideways across the boot.

The edge of the number plate recess is more difficult as it need to be blended in. Rub upwards from the number plate recess to get the edge and then rub sideways along the edge every so often to round it off slightly.
Sight along the edge from one side of the boot and you will see any imperfections in the line.





The whole boot should be rubbed down to remove the laquered finish on the paint and to roughen it up.
Yellow filler primer will fill any small airholes in the filler and most importantly will reveal any imperfection.
Dont be surprised if there are quite a few hollows and bumps.
If not - well done!
Re-sand and re apply primer until your happy with the finish.





Finished result.
Take the car to be sprayed professionally or get the compressor out (for a later guide)





The cost was p38 / p40 from halfords, the paint / laquer and lots of elbow greese.
Hope this of some help /interest to people.

smooth scuttle guide if people want....?

Chris


[Edited on 26-11-2003 by CRB 553]
CRB 553
Member

Registered: 5th Apr 02
Location: NE Drives: Punto GT
User status: Offline
23rd Nov 03 at 22:14   View User's Profile U2U Member Reply With Quote

removing the no. plate recess is not too dificult either, i might do a welding tutorial if its of any help lol,

The hard bit is the amount of p38 u use and the time it takes to get it perfectly flat!
Trotty
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Registered: 22nd Feb 01
Location: Bristol
User status: Offline
23rd Nov 03 at 22:15   View User's Profile U2U Member Reply With Quote

Excellent stuff

If you do want to expand on it anymore please do so, and I'll get it added to the Tutorials and FAQ's section
CRB 553
Member

Registered: 5th Apr 02
Location: NE Drives: Punto GT
User status: Offline
23rd Nov 03 at 22:17   View User's Profile U2U Member Reply With Quote

yeh i could do
johns purple beast
Member

Registered: 7th Nov 03
Location: herts
User status: Offline
23rd Nov 03 at 22:35   View User's Profile U2U Member Reply With Quote

looks good m8 can come do mine if ya want
jamesw
Member

Registered: 28th Jun 02
Location: Station Town, County Durham
User status: Offline
23rd Nov 03 at 22:43   View User's Profile U2U Member Reply With Quote

thinking of doing my scuttle soon so would be cool if you could post a guide.

JW
CRB 553
Member

Registered: 5th Apr 02
Location: NE Drives: Punto GT
User status: Offline
23rd Nov 03 at 22:54   View User's Profile U2U Member Reply With Quote




James this is my scuttle during smoothing, didnt manage to take many pics unfortunetely but i'll get a pic of the finished result and do a guide.
waynep
Member

Registered: 20th Apr 02
Location: london
User status: Offline
23rd Nov 03 at 23:39   View User's Profile U2U Member Reply With Quote

nice one mate much appriciated looks the bollox
CRB 553
Member

Registered: 5th Apr 02
Location: NE Drives: Punto GT
User status: Offline
23rd Nov 03 at 23:47   View User's Profile U2U Member Reply With Quote

cheers dude...
waynep
Member

Registered: 20th Apr 02
Location: london
User status: Offline
23rd Nov 03 at 23:59   View User's Profile U2U Member Reply With Quote

im wantin to smooth but but a i hav no garge and b i dont think i wood finish in one day so car wood b left unfisshed and lookin crapola its taken me 6 months to smooth half the side of my euro rear LMAO o and im lazy as hell.. and BROKE and a student and a part time werker
CRB 553
Member

Registered: 5th Apr 02
Location: NE Drives: Punto GT
User status: Offline
24th Nov 03 at 00:04   View User's Profile U2U Member Reply With Quote

lol, am a student aswell. I know wot u mean it does sortov take ya car off the road for a bit, even though u can get p38 wet it soaks in the water and u'll have to dry it out......

I wud do it for people and have been thinkin about it but got no time at the moment, could also sell scuttles etc but not sure....

[Edited on 24-11-2003 by CRB 553]
Adam-D
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Registered: 11th May 02
Location: Cheshire
User status: Offline
24th Nov 03 at 01:50   View User's Profile U2U Member Reply With Quote

nice job i bet sanding all that p38 took ageeesss

looks well smart
dave17
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Registered: 3rd Sep 02
Location: Greater London
User status: Offline
24th Nov 03 at 02:50   View User's Profile U2U Member Reply With Quote

lol uve got a golf cart!! how fast it go??
CRB 553
Member

Registered: 5th Apr 02
Location: NE Drives: Punto GT
User status: Offline
24th Nov 03 at 12:18   View User's Profile U2U Member Reply With Quote




not as fast as the performance grass-cutter, top left !
Dan-P
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Registered: 26th Jun 02
Location: London
User status: Offline
24th Nov 03 at 12:21   View User's Profile U2U Member Reply With Quote

That looks class would love to do that to my car!!
James@CCC
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Registered: 10th Nov 03
Location: Eaton Bray, Bedfordshire
User status: Offline
24th Nov 03 at 13:24   View User's Profile U2U Member Reply With Quote

i recently did this last weekend, mines lookin quite good, but yours does look quality in those pics. I did it pretty much the same way, but this guide woulda helped a load.

good work mate
James@CCC
Member

Registered: 10th Nov 03
Location: Eaton Bray, Bedfordshire
User status: Offline
24th Nov 03 at 13:25   View User's Profile U2U Member Reply With Quote

o, and i also like the way u blocked out ur number plate in one of the pics. well never find out what it is by looking at any of the other 3
Deepan
Member

Registered: 19th Nov 03
Location: Dunstable, UK
User status: Offline
24th Nov 03 at 14:13   View User's Profile U2U Member Reply With Quote

This looks sweet. I was going to get my entire tailgate smoothed (inc numberplate recess) but now I'm not so sure... If I don't, at least I don't have to worry about relocating my number plate (and light).

Cool, thanks for the guide mate!

-[ Deepan ]-
corsa120
Member

Registered: 4th May 02
Location: Northamptonshire
User status: Offline
24th Nov 03 at 16:54   View User's Profile U2U Member Reply With Quote

funny every1 says it looks sweet my car looks exactly the same at the back same bumper etc in star silver, an alot of peeps slated it lol peeps make me laugh
CRB 553
Member

Registered: 5th Apr 02
Location: NE Drives: Punto GT
User status: Offline
24th Nov 03 at 19:15   View User's Profile U2U Member Reply With Quote

corsa120- it must be the blue lol

Corser- yeh realised that when i posted doh! am not really bothered neway so i didnt change it lol

Deepan - cheers. I didnt want my no. plate to be on the reiger and i could leave my light thats why i didnt bother, mayb a future project...i dunno.
Kris TD
Member

Registered: 25th Mar 02
Location: Ware, Hertfordshire
User status: Offline
24th Nov 03 at 19:47   View User's Profile U2U Member Reply With Quote

you fitted a solenoid? i would do the smooth boot no problem but wouldnt know where to start with the solenloid. cheers.
AdamF
Premium Member

Registered: 24th Apr 02
Location: Bexhill, East Sussex
User status: Offline
24th Nov 03 at 21:01   View Garage View User's Profile U2U Member Reply With Quote

looks good mate but i really would hasve welded it mate

who painted it btw?
CRB 553
Member

Registered: 5th Apr 02
Location: NE Drives: Punto GT
User status: Offline
24th Nov 03 at 21:01   View User's Profile U2U Member Reply With Quote

yeh Kris i have done a solenoid, u just use the existing wiring for the wiper motor and then cut into it in the pasenger footwell near the fuel pump relay.

Just u2u if u have ne questions on it
AdamF
Premium Member

Registered: 24th Apr 02
Location: Bexhill, East Sussex
User status: Offline
24th Nov 03 at 21:07   View Garage View User's Profile U2U Member Reply With Quote

looks good mate but i really would have welded it

who painted it btw?
wainey
Member

Registered: 20th Oct 02
Location: walsall west midlands
User status: Offline
24th Nov 03 at 21:13   View User's Profile U2U Member Reply With Quote

quote:
Originally posted by AdamF
looks good mate but i really would have welded it

who painted it btw?
i was thinking the same, looks a really good job mate, but it cant be that strong surely? mine was welded when done! but good job

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