Powerhouse Cover, Paint and Pits

[Tom Wesenberg]

Someone asked the other day how I would deal with the rust pits shown in this powerhouse cover. After sandblasting and tapping out the dents I spayed it with black sandable primer, then sanded that and sprayed it again. I then baked it in the oven for 12 hours at 170*. Again I sanded the primer and gave it a thin coat of glazing putty. Go very thin with the putty or you'll make a lot of extra sanding for yourself. I then sanded the glazing putty so only a small amount is left to fill the pits. Now it's ready for the final coat of gloss black. After the black dries for a few hours I'll bake that in the oven for at least 12 hours at 170*. If it wasn't being shipped in a few days I could just let it dry for several days at room temp.

I bent a wire coat hanger to hold the bail wire on the cover for hanging. I paint the inside of the cover also, although originally it was left plain. Now, I'm not a painter or bodyman, so there may be a better way, but so far this has worked well for me. The last picture has the wet look because I just finished spraying the cover for the picture. It'll look better after it dries.

If the rust pits are deep I would consider just buying a repro cover. The reproduction covers are excellent both in looks and fit.

[wrndln]

Tom,
I saw your powerhouse cover tool last night at the club clinic - nice job. I was wondering what the bolt is for. Is it to just bolt the tool to a bench or something to keep the cover from slipping around when working on the cover?
Rusty Nelson

[Tom Wesenberg]

Rusty, I need the bolt for turning it, and now it works to hold the tool in the vice or bolt it to something during dent removal.

[al's28/33]

Very nice work Thomas! A skilled craftsman willing to pay attention to every detail!

[glenn in camino]

My experience with glazing putty is that over time it continues to shrink making the pits reappear.

[fiddlybits]

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I always repair pitted metal with lead.... I prefer the results.

[glenn in camino]

Originally Posted by fiddlybits

I always repair pitted metal with lead.... I prefer the results.

Bondo in small amounts works good too, and will probably outlast you and your car.