Now for the bonnet repairs. I had previously stripped off the old paint and bondo, and sprayed with cheap rustoleum primer to arrest further rust while it was waiting to be worked on. But there were still the dents, holes, and surface rust to deal with. Some of the rust was deep and had to be ground out and etched with phosphoric acid to get into the deep pits. Additional metal straightening and welding of old holes was done.
Next, the bonnet is skim coated with Dura Glass filler which is sanded down to about 1mm average. Some spots are a bit thicker. But the bonnet gets a lot of flexing, so the Dura Glass covering the larger area like this reduces the possibility of cracking or showing the transitions between filler to metal. Corners of the wings are matched to the bonnet edge, and the panel gap lines are getting fine tuned