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 - Restoration Story: Fordson Major - by Anthony West. George bought his Fordson Major from a an implement sale about 18 years ago for £200.00 (UK). There is no known history regarding its origins or what service it had done, but the following work was undertaken alone to bring it up to show standard. From the engine number, it was found that this Major was produced late 1946. It was almost complete but had various parts that would definitely need replacing.
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