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Sportster Motorcycle General Discussion and Problems For discussing problems about your Sportster motorcycle that don't fit anywhere else.

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  #1  
Old 29th January 2010
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Default best way to remove bondo

So the po of my ironhead did a bolt on hard tail and welded it then filled it with bondo. So what's the best way to remove the bondo? I was thinking a wire wheel in a drill maybe.
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  #2  
Old 29th January 2010
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Bondo is quite brittle and I've used a pick-like hammer to knock it loose in the past. A chisel will also work.

Eric
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  #3  
Old 29th January 2010
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I read in hot rod mag that aircraft paint stripper works well, may require several applications if the bondo is thick.
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Old 29th January 2010
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Bondo will also soften with heat. If you're planning on repainting your frame you could use a propane torch to heat the Bondo and it should crumble pretty easily.

Eric
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Old 29th January 2010
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a small HAMMER and a chisel.
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Old 30th January 2010
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Quote:
Originally Posted by dr.feltersnatch View Post
So the po of my ironhead did a bolt on hard tail and welded it then filled it with bondo. So what's the best way to remove the bondo? I was thinking a wire wheel in a drill maybe.
I ose a small sand blaster with corn cob or wallnut shells, in a pinch a good quality paint stripper works well.
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Old 30th January 2010
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All great suggestions..How about 100-80 grit sandpaper..works very well specially with an orbital sander or a little elbow grease

Bondo is a funny thing..it's strength depends on how hot it was mixed, (catalyst used) or how much moisture it's absorbed..Still a pain in the arse to remove.
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Old 31st October 2011
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Any shop that does powder coating will strip ity for about $50. They bake the frame in 600 degree oven which turns the bondo into ash and then they media blast it.
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Old 31st October 2011
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I guess I should update this thread huh? I ended up using a sawzall and basically rebuilt a bunch of my hardtail section. After I saw the very sketchy welds under the bondo I just cut it out and welder in some new tube.
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