1) Rust removal: wire wheel on angle grinder, followed by Ospho treatment inside and out, then repeat. For latch, Dremel tool with wire wheel, then Evapo-rust in an ultrasonic cleaner.
2) Hole repair (was used as a battery box): 1/16" sheet metal patches bonded to inside with JB Weld.
3) Dent removal: body hammers and dollies. Excellent way to avoid watching the "debates" on TV, very therapeutic.
4) Dent filling: many layers of lightweight body filler, sanded with my new set of blocks. Discovered rolls of Duragold sandpaper are much better and cheaper than sheets, and 3M lightweight filler sands much better than NAPA store brand. I wasn't sure the filler would be flexible enough for this thin metal, but so far it seems fine.
5) Dismantle and repair latch, cut a new key
6) Electroplate latch mechanism steel parts with nickel-- surprisingly easy!
7) Paint with rattle can enamel. Primer, then sealer, then top coat. Last project I learned how important sealer is when you've used body filler. This time I discovered how hard it is to paint inside of box with rattle can, and how hard it is to keep a wet edge when spraying a 5-sided object. Broke in my $50 Home Depot paint tent-- definitely reduced setup and cleanup time in my garage.
Next time I will add a guide coat step to the body work, since gloss black shows the tiniest defects. I'm guessing no one but you guys would see them, but a guide coat seems like a simple way to judge when I'm really done sanding.
I highly recommend a small project like this for anyone who wants to learn the basics and build some confidence. I think I'm ready for some bigger body panels now.
