- 1). Remove your stock kick panel from the car and take it to a well-ventilated area, then set it lying face-up on a couple of soda cans. This will keep the panel off your work desk and give you complete access to all sides.
- 2). Clean the panel with rubbing alcohol and spray all sides with two coats of mold-release agent, allowing about 15 minutes in-between coats. Load your HVLP gun with fiberglass molding gelcoat and spray the entire kick panel with gelcoat. Include any tabs on the sides and back, and allow the gelcoat to set up.
- 3). Mix up a batch of fiberglass resin and hardener, according to the package directions. Paint the kick panel with resin and lay on a single layer of fiberglass mat, then use a resin-saturated paintbrush to smooth it and drive the bubbles out. Place your paintbrush into a jar of acetone while the first layer hardens. Apply another layer of fiberglass.
- 4). Flip the mold over and use a rotary tool and cutoff wheel to carefully cut the old kick panel into several pieces. Maintain a very steady hand and avoid cutting all the way through the kick panel and into the gelcoat beneath. Carefully pull the kick panel pieces out. Run your finger over the inside of your fiberglass to remove any clinging release agent.
- 5). Apply two more coats of mold-release agent to the inside of your mold, then repeat Steps 2 and 3 to build up your new kick panel. Allow the fiberglass to set up for at least an hour.
- 6). Flip the mold over, and very carefully cut through the mold with your rotary tool. Stop when you see the orange gelcoat, then use a razor blade to cut through the gelcoat on the mold. You may need to cut it into four or five pieces to remove it. Carefully pop the pieces free. Drill out the panel mounting holes before applying filler.
- 7). Trim the edges of your new kick panel with a cutoff wheel, then smooth them and the rest of your panel with 180-grit sandpaper. Coat the panel with polyester body filler, then smooth it with more 180-grit, then 500-grit sandpaper. Fill any small scratches with spot putty, then get it flat with more 500-grit sandpaper. Spray on the gap-filling primer, sand it smooth with 1000-grit sandpaper and send the kick panel out for paint.
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