Site hosted by Angelfire.com: Build your free website today!
Filling Cavities and holes with Bondo.



This is my tutorial on filling a pickup cavity using Bondo. There are two ways to do this. The first way is to make a peice of wood to fit inside the cavity and glue it in with titebond then fill it with bondo. This method takes longer and is only necessary if the area of filling will have stress on it in the future (i.e. bridge screw, etc.). The other is to completely fill the cavity with bondo. I will describe both. I will also describe how to fill unnecessary pot holes.


BONDO WITH PEICE OF WOOD



1. Make sure the area to be filled is completely rid of any paint or dust.
2. Using a bandsaw cut the peice to the approximate size of the cavity to be filled. To do this I took a peice of paper and set it on top of the cavity and lightly scribbled on it and you can see the outside lines of the cavity then cut out the peice of wood.
3. Glue it in using titebond, not titebond II, just regular old titebond.
4. Level sand to make sure the top of the peice of wood is at or below the top of the guitar.
5. Blow out any dust from inside the sanded cavity.
6. Mix the bondo on anything thats non absorbant and somewhat smooth, a plastic bowl worked fine for me. Follow the directions on the can for proportions.
7. Using a scraper put some bondo in the holes left from the imperfections of the wood peice inside of the former pickup cavity.
8. Step 7 most likely wont be your last pass with the bondo as the bondo will sink farther into the holes, but it is a lot easier to fill the holes after the first pass is dried and sanded. So once the first is dried, sand it level.
9. Go over the holes again and again sanding in between passes with any grit below 150. Do this until you are satisfied with the final product. Sand to 220 and you are ready to go.




Completely filling with Bondo.



1. Blow out any dust from inside the cavity. Make sure it is somewhat clean, no huge mountains of dirt or anything.
2. Mix the bondo on anything thats non absorbant and somewhat smooth, a plastic bowl worked fine for me. Follow the directions on the can for proportions.
3. Using anything to hold the bondo put some bondo into the former pickup cavity.
4. Step 3 most likley wont be your last pass with the bondo as the bondo will sink farther into the cavity, but it is a lot easier to fill the holes after the first pass is dried and sanded. So once the first is dried, sand it level.
5. Go over the cavity again and again with the bondo sanding in between passes with any grit below 150. Do this until you are satisfied with the final product. Sand to 220 and you are ready to go.




Filling Pot holes with bondo.



1. Going from under the guitar in the control cavity tape the bottom of the hole to contain the bondo.

2. Fill it with bondo.
3. Let'er dry, sand, and yer done.