Building the Perfect Finish: A Deep Dive Into Project Cheap Camaro’s High-Build Phase

The Cheap Camaro project has transformed significantly from the abandoned relic initially discovered in a trailer, and now, with the help of students at Alliance High School, the exterior paint application is on the horizon. As spring break arrived in March, the team had successfully aligned all body panels and blocked the epoxy surface down to a flat finish.

While the Camaro’s body had a majority of new or salvageable metal, some areas revealed imperfections once the students began sanding the epoxy. To address these issues, they introduced a polyester high-build primer-surfacer, an application that can be likened to sprayable body filler. Ideal for novices, this primer is forgiving and easy to reinstate as needed. With previous lessons in sanding under their belts, it was the perfect material to work with as the new semester began.

Specific areas of concern on the Camaro included the roof panel and rear sail panels where the new quarter panels integrated with the original roof structure. However, to achieve a uniformly smooth finish, it became clear that a full-body application of this primer was necessary.

Assemble, Disassemble, Repeat

The next step involved careful disassembly of the vehicle—removing doors, fenders, hoods, the cowl, and trunk lid—while retaining the carefully set alignment. With guidance from Kincaid and the students, a practical plan emerged. They utilized 1/8-inch drill bits to create alignment holes through the hinges and mounting flanges for reinstallation precision.

By drilling holes for 1/8-inch steel rods into each hinge, they developed a method to keep the alignment intact during the reassembly process. Once these marks were made, it seemed the reassembly would progress smoothly, allowing the team to proceed with taking the vehicle apart.

During the disassembly, each bolt was organized into labeled bags, while fender shim packs were constructed using masking tape and permanent markers for clarity in reinstallation.

After complete disassembly, the team dedicated a full day to prepping each panel, applying 80-grit sandpaper to the edges and inaccessible jambs. The next step was ensuring cleanliness; the panels were treated with AcryliClean and air-dusted to eliminate any contaminants prior to primer application.

In the auto shop class, a large inflatable spray booth was set up. This controlled environment effectively filtered air, eliminating dust and debris from the painting process.

For primer application, the Eastwood HVLP-style P500 primer gun was selected. This gun operates efficiently at 9.5 cfm and 30 psi, making it compatible with common home compressors. Its design minimizes overspray, ensuring the majority of paint adheres to the surface rather than dispersing into the air.

To achieve the optimal spray, the gun was fitted with the widest tip available—a 2.0 mm size. The application required clean, dry air, demanding an air and water separator to prevent contamination from the compressor.

Spray Time

Staying consistent with a single paint system is essential for successful results, and the crew selected Eastwood’s Contour Polyester Primer-Surfacer as it was compatible with the previously applied epoxy. The primer should traditionally mix at a ratio of 5% catalyst by volume for effective application.

However, in an early mixing attempt, the catalyst was inadvertently measured incorrectly, causing the mixture to harden rapidly in the spray gun. This setback underscored the importance of precise measurements and quick work once mixing is initiated, as time is critical.

After cleaning the gun promptly, the team made a fresh start, measuring accurately and maintaining flow at 30 psi while keeping the gun tip about six inches from the spray surface. With adjustments at maximum, they aimed for a consistent and even application across the entire vehicle.

Employing a 50% overlapping spray pattern, the team strategically covered all surfaces to ensure thorough coverage, focusing additional time on higher-concern areas. After the initial coat and a brief five-minute curing time, they proceeded with additional coats.

Ultimately, just over a gallon of polyester primer was used, mixing only enough for the spray gun at one time to avoid wastage. With help from classmates, tasks like mixing and gun cleaning were more efficient.

After completing the panels, the spray gun underwent a thorough cleaning process to prepare it for future use.

After applying the primer, panel surfaces were allowed to cure for a week before the next stage. Although the polyester is typically dry to touch in about an hour, this extended wait ensures the panels firm up entirely.

Sand and Sand Again

Upon returning from spring break, students jumped into reassembly, which progressed swiftly due to precise previous alignment efforts. The assembly was crucial for ensuring that all panels were aligned to the body as a cohesive unit rather than individual elements.

While the polyester finish initially lacked smoothness, the subsequent sanding process with 120-grit sandpaper easily smoothed out imperfections. This unified approach to working with the car as a single unit enhances the consistency of reflections across panels, leading to a more professional finish.

Employing the guide coat allows for efficient identification of lows and encourages gradual sanding using various grits, subsequently progressing up to 320-grit. Depending on the observed condition, the students may need to respray more polyester primer or proceed to a two-component primer before the final paint stage.

This ongoing sanding and refinishing process is instrumental in achieving the visual quality and flawless appearance expected from the finished project. Each step is critical in ensuring that the 'Cheap Camaro' reaches its maximum aesthetic potential.

The journey towards a standard of excellence continues, with the entire team eager to witness the transformation of the Camaro as it moves closer to its completion.

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