PD-0100: Light Body Repair and Surface Prep Process

Proper light body repair and surface preparation are key components to a quality paint finish. This standard operating procedure (SOP) covers the light body repair process.


Step-by-Step Instructions

  1. A technician should review a work order to ensure that all parts to be painted are present and repairs are understood.
  2. Wash the vehicle with water and car wash specific soap or pressure wash the vehicle including wheel-opening areas. Rinse and dry thoroughly. Clean the repair area with a regionally approved surface cleaner and a clean towel. Dry thoroughly.
  3. Remove Paint
    Use a DA sander with P80 grade paper. Abrade the repair area and continue out past the damage by 2–4 inches. Remove remaining coating from edges, body lines, and recessed areas with a general-purpose scuff pad or equivalent. Blow off with clean, dry air and re-clean the area with surface cleaner and a clean towel. Dry thoroughly.
  4. Body Filler
    Mix and apply filler per manufacturer recommendations. Refer to OEM Technical Service Bulletins. The use of Epoxy Primer may be required before applying body filler on some OEM makes and models.
  5. Sand Filler
    Use a guide coat to highlight imperfections. Block sand body filler with P80-P100 grade paper. Re-apply body filler as necessary. Use guide coat between sanding steps to highlight imperfections. Final block sand the body filler with P180 grade paper removing guide coat and remaining imperfections. Clean sanded area with dry, clean air and a tack cloth.
  6. Mix and Apply Glaze Filler
    Mix and apply glaze filler over the entire repair area from paint edge to paint edge. Allow the glaze filler to cure completely.
  7. Mix and Apply Glaze Filler
    Blow off the repair area completely removing sanding dust from the surface. Mix and apply glaze filler if required per manufacturer’s recommendation. Keep the glaze within the primer featheredge area. Allow glaze to cure completely.
  8. Featheredge Paint
    DA sand the featheredge area with P280-P320 grade paper. Blow off the area with clean, dry air.
  9. Final Inspect
    Inspect for quality. If repair quality is good, proceed to an undercoat application process.

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