Control Panel Restoration

How often have you had a control panel that would work great if it only didn’t have too many holes? Never quite sure how to prep the panel, or what materials to use? This page will try to help you.

Here’s our starting point, an original well worn overlay on a panel with too many holes.
I’ll assume you know how to clean your panel to the bare metal and go right to the first thing you’ll need to fix the holes. Electrician’s plugs which are easily found at home improvement stores.
Once you have your plugs, time to mix up some epoxy and put it on the panel from the back side where the metal plug will go. Basic 2 part epoxy mixed with a popsicle stick.
Now, if all’s gone well you have something like this. Your holes now have some nice solid metal behind your unwanted holes held firmly with epoxy.
Now for the bondo. I always get asked just how to mix it so here’s a picture of the right amount of hardener in relation to about an ounce of bondo. Mix very quickly because bondo will harden quickly!
Once you mix the bondo you’re looking for a consistent pink color like this. Too dark and it hardens too fast, too light and it won’t harden at all. This is a good medium for maximum working time with proper hardening.
Now, while your bondo is still workable, quicky use a scraper to fill your open metal holes mounding the bondo slightly over the surface. Aesthetics are not important, just try to get it solid with no air pockets!
OK, now we’ve technically fixed our holes. Grab your dust mask and orbital sander and carefully sand the mounded up bondo flush with the panel. Take your time and make it as level as possible. If you dig too deep just add more bondo and repeat the process!
Whew! that was fun wasn’t it? Now just paint the panel and apply your new overlay and a beautiful panel is reborn.
I hope this little tutorial helps you with your panel. Sometimes it’s the simplest fixes that yield the best results!