We all know it, we all love it, and the guy parked outside of the 7-11 covered his car in it. What is it? Polyester body filler, better known by the almost generic trademark, Bondo. There’s a lot more you can do with Bondo than fairing in that sweet body kit, bro, and [Eric Strebel] is here to show you how far you can push the mechanical properties of polyester body filler.
We didn’t always have polyester body filler. In the days before OSHA, auto body workers would use a torch, bricks of lead, and a grinder. You can check out a video of the era before OSHA here. Needless to say, vaporizing and grinding lead in your shop isn’t the greatest idea, and there had to be a better way. This led Robert ‘Bondo Bob’ Spink to invent a much less toxic auto body filler that we now know as Bondo.
For the beginning of the demonstration, [Eric] mixes up a cup of polyester body filler with a few special additions: he’s using printer ink to get his mixture to something other than that one shade of pink we all know. Although Bondo is a bit too thick to cast, he did manage to put a little bit of it in a square mold, a PVC pipe, and applied a little to foam and wood. It’s enough for a demonstration, but for the actual ins and outs of machining Bondo we’re going to have to wait until [Eric]’s next video. Until then, you can check out this introduction below, or look at his previous work on free-form sculpting of uncured Bondo.