Q: We refurbish a large volume of metal parts that have dents in them. I think we have tried most, if not all, the high-temperature fillers, with poor results. These fillers are very expensive and have adhesion problems and bubbles forming in the finished coating.
We have used “Thermobond-3,” “High Temp Lab-Metal,” etc. We have had best results using “All-Metal,” a high-metal-content, regular-temperature body filler.
We use thin coats, allowing 24 hours to dry between coats. Then we cure it out around 275°F. This is OK but expensive and very time consuming. Are you aware of any products or techniques that will help us?
A: Repairing dents in parts can be a nightmare. And I agree, most high-temperature fillers don’t always work. Here’s what I would do. Apply the filler as recommended by the filler manufacturer. They usually want you to apply no more than a quarter inch (6 mm) at a time and then let the material air-dry for 24 hrs. They then recommend curing the material before coating or applying another layer. I would bake the material at a relatively high temperature to drive out any volatiles that may be present in the filler. I would start at 425°F (218°C) for 1 hour.
Alternately, you can try the lower temperature fillers. If you go that route, I suggest you find something that is cured at a temperature higher than the powder you would subsequently be applying.