Paint Your Car at Home

If you want to do it right, keep the surface temp low. Orange peel needs to be knocked down with wet sanding.

If you want to do it right, keep the surface temp low. Orange peel needs to be knocked dow

`Face up to it right now: Paint and bodywork is just plain expensive. The days of pulling up to your buddy's body shop and leaving two weeks later with a car-show paint job for $5,000 is over. Today, the cost of materials can easily run $2,000 and up if you want to use top-notch materials and do the job right. Labor cost? Expect to pay $60 per hour minimum. If you can get the job done for less, consider yourself blessed. You get what you pay for.

So this leaves the budget-beleaguered car crafter with one alternative--do it yourself. You've probably heard all this before, but it demands repeating. The key to a quality paint job is all in the prep work before any color ever finds its way onto the car. Quality work involves taking your time and doing the work carefully and deliberately. It's also maddeningly tedious and very discouraging when dents keep showing up that you swear you fixed last week.

To show you that we're capable of taking on a project instead of just writing about it, we're willing to step on a few landmines firsthand. We jumped in with our buddy Jim Peterson as he was just embarking on a backyard '65 El Camino project. Jim enlisted the help of his pal Tyrone Williams, who offered his expertise in exchange for a Peterson-built 327 small-block for Tyrone's personal '66 El Camino. We offered to work with them. Isn't that how cars get built--by leaning on your buddies and trading your expertise in exchange for their help? Ya, we thought so.

It Has to Begin Somewhere
The key to any backyard project is to start with something that is reasonably sound to begin with. This particular El Camino was in fairly decent shape but still needed hours of tweaks before it was ready for paint. Once the El Camino was placed in the side yard alongside the house, everyone had a hand in searching for dents, wrinkles, and any general sheetmetal malaise. Once all the kinks made themselves known, the real work began. We started by unbolting all the sheetmetal, removing the trim and emblems, and stripping the paint.

Here's the El Camino hunkered down alongside Jim Peterson's house. Despite having two garages at his house, the bodywork was all done outside.
Here's the El Camino hunkered down alongside Jim Peterson's house. Despite having two gara
Stripping the paint can be accomplished several ways, but the quickest (if not nastiest) method is chemical stripper. We used a couple of gallons of aircraft stripper and several disposable paintbrushes. Lay the stripper on thick, let the chemicals work for about 10-15 minutes, and then scrape the lifted paint off with a Bondo spreader as shown, or with a gasket scraper.
Stripping the paint can be accomplished several ways, but the quickest (if not nastiest) m
Once the major layers are removed, you will no doubt find some rust. This is a rust hole in the lower corner behind the right front fender.
Once the major layers are removed, you will no doubt find some rust. This is a rust hole i

If the corrosion is not too bad, cut it out and make a fabricated patch to repair the hole as shown here. We used a Craftsman home 110-volt MIG welder to carefully stitch-weld the panel back in place, overlapping the welds to complete the repair. Then the excess weld was ground down to finish the metalwork.
If the corrosion is not too bad, cut it out and make a fabricated patch to repair the hole
The left front fender rusted in the same spot but the corrosion was far worse and required more major surgery. We grafted a whole new patch panel from OPG to the bottom of the fender to repair the fender like new.
The left front fender rusted in the same spot but the corrosion was far worse and required
The tailgate had a couple of bad spots where a screw-in dent puller had been used. We borrowed an inexpensive Uni-Spotter Stud welder to spot-weld pins near the dent and then used a slide hammer dent puller to carefully work the wrinkled tin. With finesse, this tool is a great timesaver. Then we removed the studs and the small weld spots and grinded it smooth.
The tailgate had a couple of bad spots where a screw-in dent puller had been used. We borr

Slinging Bondo
Anyone who tells you that Bondo has no place on a quality repair job has never done bodywork. Even the best metalsmiths will use plastic repair media to skim-coat sheetmetal to give it that mirror-smooth look. In this case, we first eliminated all rust then pulled all the large dents and finished by working them with a hammer and dolly. With that done, they mixed up some 3M Lightweight Body Filler to fill in the little dings that were too small for hammer work.

The first step is to identify the problem areas. El Caminos have huge slabs for rear quarter panels, and they're breeding grounds for parking-lot dings and minor dents along the body lines. Running your hand slowly over the panel will identify high and low spots that need attention.
The first step is to identify the problem areas. El Caminos have huge slabs for rear quart
After application of the first skim coat of plastic filler, sand in opposite 45-degree angles to prevent creating trenches with the sanding blocks. Use 150-grit sandpaper with a long sanding block to create a smooth finish. After a second skim coat, we used black enamel spray paint as a guidecoat. The black paint will indicate low spots that will need more sanding.
After application of the first skim coat of plastic filler, sand in opposite 45-degree ang
If you want to push the job a little faster, you can hit the first skim coat of Bondo with a DA using 150-grit sandpaper.
If you want to push the job a little faster, you can hit the first skim coat of Bondo with

After short sessions with the sanding blocks, your hands are the best detectors of remaining low spots or wrinkles.
After short sessions with the sanding blocks, your hands are the best detectors of remaini
The arrow indicates a low spot in the Bondo that will need attention. If there is sufficient thickness, this can be sanded flat. If not, a very thin application of Bondo will fill the void.
The arrow indicates a low spot in the Bondo that will need attention. If there is sufficie
The '65 El Camino also has a distinct crease or body line that extends the length of the rear quarter-panels. Plastic filler can hide this line, so place a strip of 3M blue tape just above the top of the crease as a guide. Then sand up from the bottom to this line. Then apply another line of tape on the bottom edge of the line and sand down from the top. This technique will return the body line to the quarter-panel.
The '65 El Camino also has a distinct crease or body line that extends the length of the r

The skim coats of Bondo are what take a serious amount of time. Just the hood, front fenders, roof, quarters, and the tailgate involved 10 days of part-time work--roughly 30 hours.
The skim coats of Bondo are what take a serious amount of time. Just the hood, front fende
Since we wanted a perfect El Camino bed that will never see anything rougher than a lamb's wool blanket, the dent pounding and plastic filler work also extended to those horizontal and vertical surfaces.
Since we wanted a perfect El Camino bed that will never see anything rougher than a lamb's
After removing previous-owner primer, we discovered Bondo and some light surface rust on the top, which we quickly removed with a dual-action (DA) sander. Smoothing slight wrinkles by using a small amount of Bondo is exactly how plastic filler is supposed to be used.
After removing previous-owner primer, we discovered Bondo and some light surface rust on t

Blocking the roof involves the same work. Remember to sand in 45-degree angles to create a smooth, even finish. Ideal plastic filler thickness should be only a few hundredths of an inch thick.
Blocking the roof involves the same work. Remember to sand in 45-degree angles to create a
Just before the primer goes on, it's always a good idea to hit all the panels with wax and grease remover to prevent fish eyes and other imperfections.
Just before the primer goes on, it's always a good idea to hit all the panels with wax and
Mere filler primer does not seal against the elements, so we elected to first spray the El Camino with DuPont Nason Ful-Poxy primer, which is a combination of sealer and primer.
Mere filler primer does not seal against the elements, so we elected to first spray the El

The front fenders were left off the car to allow painting everything with more control and to get the primer-sealer around all the fender edges.
The front fenders were left off the car to allow painting everything with more control and

Applying Primer
Folks who do not work on cars sometimes need a mantra or some kind of code to keep them on track. Anyone who does bodywork only needs to keep repeating one phrase--"keep sanding." We used red etching primer as the base primer that will adhere to the body and filler and also seal the body from the elements to prevent oxidation under the paint. Normal filler primers do not seal and will eventually allow rust to bleed through.

Here's the entire bed completely painted in the ruddy red version of the primer-sealer. Once this has cured for a couple of days, hand-scuff the primer with 150-grit to remove any surface imperfections.
Here's the entire bed completely painted in the ruddy red version of the primer-sealer. On
Even with this first primer coat, we were still a long way from being done. Next we used a Trans Star urethane light-gray filler primer. This will be used to build up the inevitable low spots.
Even with this first primer coat, we were still a long way from being done. Next we used a
This led us back to the long boards again, again using a 150-grit dry paper. Note how we've sanded through the gray primer, and in some places even through the red primer, to get an even surface on this door.
This led us back to the long boards again, again using a 150-grit dry paper. Note how we'v

Since the El Camino was stripped to the bone, we also sanded and primered the dash. We didn't make it perfect, because the top will be covered with a new dashpad.
Since the El Camino was stripped to the bone, we also sanded and primered the dash. We did
Throughout the painting process we used an affordable Craftsman HVLP gun, which requires low air pressure and applies more material on the surface rather than turning it into overspray. With the high cost of paint, this is the only way to go.
Throughout the painting process we used an affordable Craftsman HVLP gun, which requires l

Finally! Ready For Paint
After what seemed like forever, the El Camino was ready for the fun stuff. Since this has been a homebuilt budget operation from the start, we bought a big roll of inexpensive plastic sheeting and trimmed the inside of the garage to create our own spray booth. We also fashioned a small fan with a filter to keep the air moving through the garage. With the HVLP gun, the overspray wasn't as bad as it would have been with a high-pressure gun.

Material costs are a big part of any paint job. It's easy for material costs to exceed $2,000 without getting extravagant. To keep the cost in line, we decided on single-stage paint for the El Camino, using a DuPont metallic urethane called Nason Ful-Thane. This is a low VOC (volatile organic compounds) paint, which means it is environmentally friendly and you don't have to worry about poisoning the neighborhood by shooting this stuff in your garage. Single stage means that this is a one-shot deal compared to the more common but also more expensive basecoat/clearcoat two-stage paint systems. This also means you won't be able to color-sand this paint after it is applied, which makes it that much more important to get the coverage right the first time. This paint is a urethane replacement for the old acrylic enamels and will produce a good shine that will also be durable.

We're skipping over lots of details because of space considerations. For example, following the manufacturer's recommendation for mixing ratios between the topcoat and the catalyst is important. Paint manufacturers recommend mixing reducer with the topcoat to allow the paint to adjust for temperature. There are also several speeds of reducer based on weather conditions. Fast reducers flash the paint quickly for colder weather painting while slow reducers are best used in hot weather. There are tons more tricks that you can learn by asking a few questions of painter buddies and professional body men. If you're unsure, ask questions before you lay down paint and your chances of success will improve immensely. Take your time and above all, have fun.

The second coat of filler primer is used to again build up the low spots.
After the second application of filler primer, we blocked all the panels with 220-grit wet paper and again used a guide coat to indicate the low spots. Final blocking used 360-grit paper and plenty of water.
After the second application of filler primer, we blocked all the panels with 220-grit wet
Once the El Camino was in the garage, we hung plastic sheeting over the walls to protect against overspray. Just before we started to spray, we swept the garage floor and sprayed it down with water to keep dust to a minimum.
Once the El Camino was in the garage, we hung plastic sheeting over the walls to protect a

Paint Tricks
Since this was a budget-driven paint project, we used less-expensive materials for primer, fillers, and especially the topcoat. In this case, we opted for a single-stage urethane paint. If you're looking for a better overall finish with more gloss, two-stage basecoat/clearcoat paints offer more depth and clarity but are much more expensive. It's not unusual to pay more than $350 for a gallon and a half of basecoat color followed by a gallon and a half of clearcoat that will run $150 or more. That comes out to around $500 just for the topcoat, reducers, and hardeners. Other attendant goodies could be another $50. We won't even get into pearls and specialty paints that can run much more. We'll leave those paints to the pros.

After a final shot with wax and grease remover, shoot time had finally arrived. We shot this photo with the garage door up just to have a photo of technique with the gun at a 45-degree angle to the work surface. Overlap the paint and keep the gun moving. Let the paint dry for at least two days before starting the color-sanding and buffing process
After a final shot with wax and grease remover, shoot time had finally arrived. We shot th

MaterialsDESCRIPTION PN SOURCE PRICEDA discs, 80 grit, 15 ct. 8A080

Abrasiveresource.com $10.05DA wet sheets, 220 grit, 15 ct. 8A220

Abrasiveresource.com 9.003M longboard 150 grit, 20 ct. 32569 local

supply 15.533M longboard 80 grit, 50 ct. 0391 local supply 30.74

3M 9x11 wet 360 grit 25361 Autobodydepot.net 26.26

3M filler, 1 gal. 5801 Autobodydepot.net 11.99

3M tube hardener, 3 oz. 5831 Autobodydepot.net 2.85

3M green spot putty, 21 oz 5960 Autobodydepot.net 13.03

5Star wax/grease rmvr, gal. 5900-1 Ditchek.com 13.00

Transtar etch primer, gal. TRE6121 Ditchek.com 30.36

Transtar primer, gal TRE6401 Ditchek.com 44.79

Transtar, primer active., qt. TRE6934 Ditchek.com 25.40

DuPont, Ful-thane, gal. N/A your choice 133.00

DuPont gun cleaner, gal. 3924S Ditchek.com 13.56

Masking paper, roll FGE467 Ray's Paint 5.97

Aircraft stripper, 1 gal. 343-1 Ray's Paint 29.95

Total $415.48Tools

Craftsman MIG 180 20504 Sears/Craftsman 699.99Craftsman HVLP gun

15531 Sears/Craftsman 109.99Craftsman DA sander 19976

Sears/Craftsman 59.99Uni-Spotter Stud Welder, kit 4500

Autobodydepot.net 199.96Body filler spreader kit 3844

Autobodydepot.net 67.473M long board, 16-inch 5744

Autobodydepot.net 27.963M hand board, 712-inch 5741

Autobodydepot.net 13.933M hand board, 5-inch 5740

Autobodydepot.net 11.83Total $1,191.12

Note:

Depending upon usage, you will need at least one gallon of body filler, dozens of lengths of sandpaper, a half-gallon of etching primer, two gallons of fill primer, a couple quarts of activator, one gallon of reducer, and 112 gallons of color to do a full-size car like the El Camino. Establishing a minimum price is easiest--around $500 to $700. From here, the price will escalate based on the quality of the materials and how much you use. Spending $1,000 is not unusual for quality materials. The prices given above are Internet prices; expect to pay more at local stores for the convenience of getting the material immediately.

`SOURCESAbrasive Resource; Minneapolis, MN; 800/814-7358; abrasiveresource.com3M; St. Paul, MN; 888/3M-HELPS;

solutions.3m.com/en_USDitchek; Brooklyn, NY; 877/CAR-COLOR; ditchek.com

DuPont Performance Coatings; performancecoatings.dupont.com

Original Parts Group; Huntington Beach, CA; 800/243-8355; originalpartsgroup.com

Ray's Paint & Supply; North Hollywood, CA; 818/769-4348

Sears, Roebuck & Company (Craftsman); 800/377-7414; sears.com/craftsman

TCP Global; San Diego, CA; 858/909-2110; autobodydepot.net