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Thanks for the kind words guys. Repair took me about 8 months solo in my garage. I have a background in auto refinishing and light structural repair before going into engineering.
I used U-POL Raptor tintable bed-liner sprayed out of a shutz style gun using a basic 30gal garage compressor.
I tinted the bottom with a few drops of Dove grey; The almond milk color of the U-POL with a dash of grey matched the tank and existing underside pretty well.
I tinted the topside with a pint of mixed base coat from a local autobody supplier. The color matches better in person. The flash in the photo gives it away.
General notes on bed-liners:
1) They hate to be sprayed thick. They will crack over time if too much is laid on and its easyish to do with a schutz gun which has minimal metering.
2) Do an initial thin brush coating in corners and hard to reach areas. Apply a more general application overall including the hard to reach areas on a 2nd pass. You will over apply in the hard to reach areas if you use the Schutz to blast extra in there.
3) Superglue squirted through a small tip is a good way to address smaller undercoat cracks. squirt it in until it starts to come back out. You then know your crevice is filled and will not allow moisture in. Larger cracks or delaminations need to be pulled off and repaired.
4) You do not want moisture between your undercoating and structure so prep here is very important.
Keep going Coultl. Your 3D printed tools and jig ideas are cool.
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