The first coat of Bondo can be leveled with a DA sander. Subsequent coats, (and there WILL be subsequent coats), can be leveled with an air file. Final coats need to be done the old fashioned way, by hand with a sanding board long enough to cover the entire area.
When you think you have it level, prime it and apply one or more coats of spot putty. The spot putty will fill minor imperfections and sand scratches. You may have to apply several coats of spot putty, using increasingly finer sand paper.
Then build up several coats of primer and sand again. By the time you're ready for the finish coat, you'll be up to 600 to 1,000 grit paper.
Keep in mind automotive finishes are contrary by nature. They just love to show off sand scratches and imperfections when you thought you had perfection.
It's a painstaking and time-consuming process, but after 30 years of involvement if there are any shortcuts, I've never found them.
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Today's Featured Article - A Cautionary Tale - by Ian Minshull. In the early 1950s my father bought an Allis Chalmers B and I used it for all the row crop work with the mangolds and potatoes, rolling and the haymaking on our farm. The farm and the Allis were sold and I have spent a lifetime working on farms throughout the country. I promised myself that one day I would own an Allis. That time event
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