Smoothing aluminium panels

[markward]

I've just had the aluminium panels on my traveller sand blasted to get rid of all the old chipped paint and they've come back looking like sand paper. What can I use to smooth the surface prior to respraying with 2 pack? I don't want to sand down the metal any further otherwise there will be none left but normal filler seems too thick to cover the whole surface of the panel and I want something that will adhere to the metal.
Thanks in advance,
Mark Ward
p.s. The new woodwork from Steve Foreman at 'Woodies' fits perfectly and looks beautiful.

[bigginger]

Filler primer? You spray it on, then sand it. No real idea if it works on ally. can't see why not...

[rayofleamington]

You need to make sure the bare aluminium is treated with the right etch primer otherwise there's no point wasting money having them painted.

Filler primer should do the job followed by a good flatting. Bear in mind that 2-pack is a lot more forgiving of surface defects than using the proper paint (Cellulose) so have a word with your sprayer to see what level he wants the primer to be flatted to.

[markward]

You need to make sure the bare aluminium is treated with the right etch primer otherwise there's no point wasting money having them painted.

That's what I was worried about, does the etch primer have to go on before filler primer, or can you get 'etch/filler primer'?

[rayofleamington]

or can you get 'etch/filler primer'?

You can get it, but I don't know if it is worth having (I know very little about painting). The best people to ask would be the Minor centres that do restorations as they must come across this very often with travellers.
You really need a good etch as it is heartbreaking to see a traveller with the newish paint flaking off the ally

[custommartin]

Hi,

As you have found, sand blasting is too harsh for aluminium.

Ideally aluminium should be bead blasted - plastic bead, crushed walnut etc. which is kinder to the material.

As a professional sprayer this is a simplified order of things;-

1)Sand the panels down - something like 240 wet and dry - USED WET
2)Spray with etch primer - the paint WILL NOT STICK otherwise!
3)Spray with filler/primer - normally straight after the etch has gone on - known in the trade as wet-on-wet.
4)Once FULLY hard flat the primer with 6-800 wet and dry - USED WET

There is slightly more to it than this but you should be ready for the top coat after stage 4)

[markward]

Thanks for all the expert advice, I've spent so much time on my Traveller's rebuild so far I didn't want to spoil things at the end.

[Kevin]

If the panels are beyond redemption ESM sell them new but they are about £25 a panel.

[chickenjohn]

I got 2 new ones from ESM for my Traveller, but if you're reasonable withe the Jigsaw and happen to have the material, I guess it would not be too hard to fabricate two ally traveller panels from sheet, using the damaged originals as templates after all, one is flat and the other has a simple single curvature bend in it.

[markward]

I got around to trying the sand blasted panels onto the new wooden frame last weekend and there were gaps all the way round the bottom of the panels. I think my predecessor was very handy with body filler. I've get new panels from MMC in Brum and they fit much better. Should have bought new panels in the first place!