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29th January 2010
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Senior Chief Know It All 2nd Class
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Join Date: Nov 2008
Location: my house
Posts: 1,434 Sportster/Buell Model: 1200c Sportster/Buell Year: 08 Sportster/Buell Model #2: Xlh Sportster/Buell Year #2: 77
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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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"A man dies when he does not stand up for what he knows is right"
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29th January 2010
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XL FORUM TEAM MEMBER
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Join Date: May 2007
Posts: 4,103 Sportster/Buell Model: Ironhead XLH Sportster Sportster/Buell Year: 1978 Sportster/Buell Model #2: Ironhead XLT Sportster Sportster/Buell Year #2: 1977 Other Motorcycle Model: Honda CBX 1000 Other Motorcycle Year: 1979
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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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1978 Anniversary Edition XLH. Wiseco 10:1 forged pistons, Andrews R5 cams, dual plugged heads with Super Port Flow, single fire ignition, Mikuni Solex 36 PHH carb, Jagg oil cooler, '73 gauges, kickstart, Barnett kevlar clutch, Progressive front springs, Hagon Nitro shocks, all-Andrews tranny. 1977 XLT, Mikuni Solex 36 PHH carb, tapered dual exhausts, Andrews Y cams, Progressive front springs, Hagon Nitro shocks.
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29th January 2010
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Biker
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Join Date: Jul 2008
Posts: 61 Sportster/Buell Model: XL883 Sportster/Buell Year: 2000
Reputation: 35
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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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29th January 2010
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XL FORUM TEAM MEMBER
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Join Date: May 2007
Posts: 4,103 Sportster/Buell Model: Ironhead XLH Sportster Sportster/Buell Year: 1978 Sportster/Buell Model #2: Ironhead XLT Sportster Sportster/Buell Year #2: 1977 Other Motorcycle Model: Honda CBX 1000 Other Motorcycle Year: 1979
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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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29th January 2010
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Chief Know It All
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Join Date: Jul 2009
Location: Rocky Mountains
Posts: 408 Sportster/Buell Model: 1200 Custom Sportster/Buell Year: 2006
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a small HAMMER and a chisel.
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30th January 2010
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Greasemonkey
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Join Date: Aug 2006
Posts: 114 Sportster/Buell Model: 1200 XLC 100th Sportster/Buell Year: 03 Sportster/Buell Model #2: 1200 50 XL 762/2000 Sportster/Buell Year #2: 07
Reputation: 169
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Quote:
Originally Posted by dr.feltersnatch
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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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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Coasty
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30th January 2010
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Ride That F'N Sportster!!
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Join Date: Nov 2004
Location: Carolina Coast
Posts: 12,046 Sportster/Buell Model: Highly modified 1200 c Sportster/Buell Year: 01 Other Motorcycle Model: H-D Street glide Other Motorcycle Year: 2013
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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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31st October 2011
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Biker
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Join Date: Feb 2010
Posts: 4 Sportster/Buell Model: XLH Sportster/Buell Year: 1976 Other Motorcycle Model: Honda Goldwing Other Motorcycle Year: 1990
Reputation: 10
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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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31st October 2011
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Senior Chief Know It All 2nd Class
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Join Date: Nov 2008
Location: my house
Posts: 1,434 Sportster/Buell Model: 1200c Sportster/Buell Year: 08 Sportster/Buell Model #2: Xlh Sportster/Buell Year #2: 77
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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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