DIY Body Panel Prep - CHP Step By Step

While we could have continued to remove the old paint with the DA sander, we wanted to showcase another method for removing the old color, namely the potent aircraft stripper. This is a harsh chemical that actually eats away the old paint. McGann grabbed a can, a mask, glove, and using a wire brush, applied it in thin sheets across the roof. From there we let each sheet sit for 10-15 minutes to dry before we began to scrape the old paint off.

Depending on the condition of the paint being stripped, you may have to repeat the process shown here. In our case, we laid down two applications of aircraft stripper and then cleaned the area with fresh solvent. The aircraft stripper is a great way to expedite the removing of paint, but be sure to work in a well ventilated area.

With the panel clear of debris, we hit the roof again with the DA sander (40-grit) and continued to sand evenly until the paint was gone. We ran our hands across the clean, freshly exposed metal to check for defects.

This is when we learned that we had applied a little too much pressure with the electric grinder. We had created small dents. These would have to be filled, but the rest was perfect for painting.

We applied a liberal coating of Eastwood's Fast-Etch spray to the bare surface of the roof. This one-step rust-fighting liquid effectively dissolves rust and leaves a protective zinc-phosphate coating. We let it soak for 20 minutes and then cleaned the surface again with lacquer thinner.

To fill the dents we had created with the electric grinder, we prepared some Eastwood body fill on a spreading plate with catalyst. McGann then ran a thin layer over the roof to cover and fill the spots. We let the body fill dry until it was almost chalky to the touch and began to sand it with 60-, 80-, then 150-grit.

With Eastwood's trick body sanding block, we began to take down the body fill. We were careful to follow the natural body lines of the roof. We worked diagonally until the low spots on the roof were filled. Once again, we cleaned the surface of the roof with some cleaning solvent to prepare it for paint.

Finally, we taped off the section we wanted to paint, covering most of the windshield and the passenger window. Using Gray Paint Primer, McGann laid down a thick coat. Primer dries quickly. We applied another coat 10 minutes later. Now all we have to do is complete the rest of the roof-no problem!