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What sanders do you use and why?

454 Views 20 Replies 11 Participants Last post by  TechNova
There are parts of my '73 Chevy Nova I am not experienced enough to even try to repair(I will leave that up to a paid professional), however, there are some minor areas where
my car has some rust which I have used a grinder to remove, I have been using a very basic sander that takes forever to make any kind of difference. I have some areas where I am trying to smooth out some body filler I applied and just can't seem to get rid of the ridge and areas where I put a bit too much body filler and it's taking forever to bring it down. Also, a couple of areas where primer was applied and I can see where the one application stopped and the other started . I would like to get rid of that. My sander wasn't made for the job and it's not doing the job. I would appreciate hearing what others are using because I'm going to invest in a few more tools and would really appreciate knowing what to look for. Is there one sander that pretty much does everything?
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your best bet
start watching you tube videos
eastwood has lots, they sell paint, bondo etc and lots of body work tools
learn how to do body work and that will help you decide what tool to use

just one example
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I took my car to bare metal with a pneumatic DA sander and 80 grit paper. Gotta have a decent air compressor for that though (60 or 80 gallon unless you like taking tons of breaks).
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your best bet
start watching you tube videos
eastwood has lots, they sell paint, bondo etc and lots of body work tools
learn how to do body work and that will help you decide what tool to use
just one exampleMEDIA=youtube]smudf-wpsoY[/MEDIA]
Great idea. I have started doing that although some of them don't mention the tools(or brand) they are using. BTW, that's a great video.
I have had good luck with Dynabrade 6" dual action sanders. Also depends on what grit of paper you are using, on filler, perhaps start with an 80 or 120 open coat and progress to at least 320 prior applying a sanding sealer then prime. The sanding sealer will fill in 320 grit or finer grit sanding marks. As stated above, lots of info on U-Tube and other resources as well. Hope this helps. Other with more experience in body work finishing will chime in. Good luck......Bob
Always match your paper grit to what the paint/primer calls for. If too rough you will see sanding marks. If too smooth the paint won't stick for long.
DA sanders are available in electric as well as pneumatics and are good for smoothing things out
Summit, Eastwood, Harbor Freight, and others have drum type strippers that are better for taking it down to bare metal.
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Do yourself a favor and buy something like this. You do not need to be trying to work any kind of filler with any form of air or electric sander until you have experience. You will need a couple of different grits of paper you can buy by the roll. I keep 80,120,240,320 and 400 grit rolls in my shop. Also a spray on or powder guide coat is important. As already related, start watching youtube videos but stay away from rust repair without welding and such.

Do yourself a favor and buy something like this. You do not need to be trying to work any kind of filler with any form of air or electric sander until you have experience. You will need a couple of different grits of paper you can buy by the roll. I keep 80,120,240,320 and 400 grit rolls in my shop. Also a spray on or powder guide coat is important. As already related, start watching youtube videos but stay away from rust repair without welding and such.

Good to know. Thank you. The air sanders are beyond my level of expertise, for now.
I've always had great luck with an angle grinder and a quick stripping disc for getting through body filler and old paint, without totally trashing the sheet metal underneath.

Fair warning: If there is significant rust hiding behind it, work slowly. The discs tend to grab sharp edges of metal, and can blow out section your trying to fix or grenade the pad.

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If you have areas of rust bleeding through your paint, chances are that it's far worse than you may expect, it's an iceberg sort of effect, where you see a little area somewhere but underneath it's much worse. A dual action (D/A) sander is great for hitting large areas where you do not want to put swirls in...because the D/A rotates on two different orbits. If you're at a place where you've got rust kicking through your finish, I'd recommend starting with a 3" angle grinder with a flap disc on it. You're going to end up cutting through paint and what lies beneath (which could be multiple layers of paint and/or bondo etc.) It's pandoras box though, because if you cut through the paint and hit a "skim coat" of bondo, you'll need to grind down around the area until you've got clean metal. You may find that it's rotted through. Then you're into cutting out the area and welding in new metal. If the metal is mostly fine, you've got two choices: either build the bondo back up to match the area around the repair and then all of the prep etc. to paint it...or you end up discovering there's a lot of bondo and you want to cut it all down.

Truthfully, anytime you're seeing rust it's usually much more involved than what you're actually seeing. I went through this on my last project that I never completed. 1957 Chevy pickup. Looked mostly awesome when I bought it. When I started working on it, I found it was packed full of bondo, when I started stripping it...I realized the entire thing was in really rough shape and it was hidden under layers of polyester and primer.
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If you have areas of rust bleeding through your paint, chances are that it's far worse than you may expect, it's an iceberg sort of effect, where you see a little area somewhere but underneath it's much worse. A dual action (D/A) sander is great for hitting large areas where you do not want to put swirls in...because the D/A rotates on two different orbits. If you're at a place where you've got rust kicking through your finish, I'd recommend starting with a 3" angle grinder with a flap disc on it. You're going to end up cutting through paint and what lies beneath (which could be multiple layers of paint and/or bondo etc.) It's pandoras box though, because if you cut through the paint and hit a "skim coat" of bondo, you'll need to grind down around the area until you've got clean metal. You may find that it's rotted through. Then you're into cutting out the area and welding in new metal. If the metal is mostly fine, you've got two choices: either build the bondo back up to match the area around the repair and then all of the prep etc. to paint it...or you end up discovering there's a lot of bondo and you want to cut it all down.

Truthfully, anytime you're seeing rust it's usually much more involved than what you're actually seeing. I went through this on my last project that I never completed. 1957 Chevy pickup. Looked mostly awesome when I bought it. When I started working on it, I found it was packed full of bondo, when I started stripping it...I realized the entire thing was in really rough shape and it was hidden under layers of polyester and primer.
Thank you for a lot of really great information. I know everything that was done on my car, including by me. I did make the mistake, however, of trying to repair a couple of areas(small) with bondo after I removed the rust. Now, I realize that all has to come out and metal welded in.
I’ve done the same. On the 1957 chevy truck I had, I messed with fiberglass mat a lot and bondo and learned I needed a welder and skills and patch panels. Life is learning.
I've always had great luck with an angle grinder and a quick stripping disc for getting through body filler and old paint, without totally trashing the sheet metal underneath.

Fair warning: If there is significant rust hiding behind it, work slowly. The discs tend to grab sharp edges of metal, and can blow out section your trying to fix or grenade the pad.

View attachment 457766
These are the absolute best that I have found to strip paint. Took my whole 71 down to bare metal. They also make small ones that work on angle die grinders for small areas
These are the absolute best that I have found to strip paint. Took my whole 71 down to bare metal. They also make small ones that work on angle die grinders for small areas


Thank you. Is there a name/brand for them?
3M calls them a paint and rust stripper. I found them very messy/dusty, and still seemed to have to attack the area with a wire wheel to get anything more than surface rust off the metal (it didn't seem to do much when there was pitting or creases in the metal).
3M calls them a paint and rust stripper. I found them very messy/dusty, and still seemed to have to attack the area with a wire wheel to get anything more than surface rust off the metal (it didn't seem to do much when there was pitting or creases in the metal).
Okay. Thank you. I may invest in both.
Wear safety glasses unless you want a chance of your eyeball getting a new piercing!
I use a porter cable sander but depending on the area, sometimes hand sanding suits best.
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