Astromech.us

So I have all the panels and pie pieces printed with the exception of the very top panel.  I started sanding.  From research online, if you plan on hand sanding, you have an enormous amount of work ahead of you.  I was lucky enough to have a received a Dremel Multi-Max oscillating tool from my wife for Christmas a year or two ago, so I have been using that.

I started with 60 grit sand paper.  This thing worked great.  I was able to sand most of the layer lines and imperfections out.  I planned on using Bondo automotive filler to fill the imperfections that were not easily sanded down.  I sanded as much as I could before using the Bondo.  As you can see, I filled the seams and any other spots I found.

The Bondo that I purchased was a two part filler.  I found that it hardened much faster than I expected, so if you’re going to use this method, plan on working fast.  I sanded everything again and inspected my work.

It wasn’t too bad, but I still found areas that needed attention.  As I said, working with the two part Bondo was a challenge.  I purchased a tube of Bondo Glazing and Spot putty.  This appears to be the exact same stuff as the two part Bondo, without having to mix hardener in with the material.  I spent some time putting on a second round.  I really spread it on the rings, hoping for a good result.

So I’ll continue sanding and sanding and sanding some more…