I've taken the old spoiler off and am in the process of smoothing the boot out ready for my 99 spec spoiler :) So far I've sanded the holes back to bare metal and punched the centre of each with a cone shaped wedge. The holes now have a nice bowl about 1.5mm deep around them ready for fibre glassing.

 

I was going to fill the holes with Dinitrol Fibrestar as you don't need to use matting, thought that since I haven't done any fibreglassing before, it would make it easier :wack:. The problem is that when I apply the filler an air bubble blows out of the hole and it won't cover :headvswal What do I do to get round this?

most bodyshops i've heard of and including myself (did it on a mk5 escort) tend to weld the holes up and grind it flat before filling, any amount of fibreglass or filler will sag or crack..in my experience anyways, although i have heard if people glueing a penny to the back first but i reckon that sounds a bit rough!

i'd weld it too, it'll do the best job. Thats what we did with the calibra

i put cardboard the other side of the hole as welding can cause the metal to worp

i put cardboard the other side of the hole as welding can cause the metal to worp

 

How did you manage that mate? I tried to put some tape on the inside but I can only reach the holes on the end. lol

my zed was allready smooth when i got it but on other things i have done like aerial holes and de locking that sorta stuff i have used cardboard

any whole whitch has not got a natural materiail to suport it like metal will shrink and or expand and therefofe the awswer is if you have a whole more than three mill it will need to be sunk .ie if you have a hole like the removale of rear wiper blade yourll need to first stop the metal struture around where your welding by tap dyind the whole and then spot and grind then when filling the whole use p40 mixeed with p38 makes for perfecbond grip and non shrink and easy to sand.no shrinkage,sorry i had a drink but ive had two bodyshops night

Some Goon who worked on my car before i owned it used a tiddly-wink and some bathroom sealer to fill the wiper hole on the tailgate and then put filler over the top!! no need to ask what happened the first tme the boot was slammed shut!