Filling in a fiberglass hole

W

Whiskyb

I have decided at the last minute to fill in my fuel door cavity. Fender is glass. What would the proper way of making sure the seam never shows to do this fuelfiller.jpg
 
I filled a hole like that on a boat. It showed when the sun heated the surface. I used kitty hair to fill it.. Then smoothed over with a filler.. Wasn't a good way to do it,but that was long ago and i really didn't know any better.. I don't know what keeps a void that large from telegraphing thru..

Shine, or someone who does vettes should answer this. Jimc could as well. He worked for a Yacht company for years also...
 
The pocket needs to come off and the opening needs to be tapered back at least 10X the thickness of the panel-more the better, surface area on the bond area is key to strength and try to keep the thickness of the repair not much thicker than the original panel so expansion rates are fairly even.
 
I think I might be better off leaving it, after all this work I would hate to have it come back and haunt me. I should of ordered the fender without the opening. Hopefully there will not be a next time for this car but if there is I will no better
 
This repair is doable and 95 percent safe...taper from the back, tape a wax paper covered form on the front and apply 2 layers of mat with VINYLESTER resin from the rear, let cure just the minimum until you can flip over and taper the top side and apply 2 more layers on the finish side...let dry just the minimum and sand and get a coat of premimum filler on it...then you have time to put it in the sun with black plastic loosely over it to cure...3 days is best...the key is to keep from applying resin to CURED resin and post curing with the black plastic, so the area has been subjected to higher temperatures than it will see in the future...I know it will be hard doing it from the 3 inch hole in the rear, but you can do it, and it will look nice...
 
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