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Old 10-02-2016, 09:53 AM   #1
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1969 18' Caravel
Dallas , Texas
Join Date: Jul 2015
Posts: 15
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how best to fill big gaps in wheel wells?

trying to do a shell off remod and i'm to the stage of putting the shell back on after restoring trailer frame and putting in new subfloor, belly pan, insulation, etc...
So now that I've put the shell back on I've got some significant gaps in a few areas. From the interior you can peer over the new wheel well and see the road below you on the outer corners of the wheel well... where you attach the shell to the new wheel well. There's also a few fairly big gaps where my shell didn't quite wrap tightly enough up against the new belly pan.. (a few pictures attached)


I bought some 'Bondo' and tried it in a small area (seen in second picture)and it seems to be a pretty rigid hard fill. I know nothing about it and have never used it before so I guess i'm just wondering if it will make a for a pretty long lasting cure to this issue.

p.s. I think i'm going to paint the belly w por15 plus top coat from the rubrail down so cosmetically I'm hoping to cover up any mismatched colors that this sealer/filler might cause.
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Old 10-02-2016, 10:09 AM   #2
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1960 33' Custom
Saskatoon , Saskatchewan
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I'd use something like aluminum tape to form a boundary then get some sealant and mix it with a solvent to make a stiff milkshake texture and pour to fill the void. I did this on my last trailer and it worked great. Flexible, lasting and waterproof

1960 Sovereign 33' Pacific Railroad Custom
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Old 10-02-2016, 10:33 AM   #3
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1969 25' Tradewind
Shasta Lake , California
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oh heck no . What you want to use is Spackle with sparkles of course.

BTW Bondo is not a sealant its a filler, It will need to be sealed.

Also POR needs to be painted over as it is not UV protected.

In any case the surface must be scuffed to give it some tooth so what ever you plan to use will stick and not fall off later.

Better yet make a patch panel and rivet it in place and seal the edges with Parrbond.
Glen & Jane 1969 all electric Airstream 25' TradeWind
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Old 10-02-2016, 12:58 PM   #4
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1971 21' Globetrotter
Arvada , Colorado
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I agree with truck, I thinned down sealant and poured into the gap ( after taping the bottom off ). Worked like a champ, no more dust.
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Old 10-03-2016, 12:01 PM   #5
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2016 26' Flying Cloud
Southlake , Texas
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I cut some aluminum sheet to cover the gaps in my wheelwells, pop riveted them in place and then sealed with Sikaflex.
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Old 10-03-2016, 06:55 PM   #6
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2003 22' International
South Bend , Indiana
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I second the Sikaflex 221. Bondo will likely crack quickly without a strong substrate under it. Aluminum patch with rivets with Sikaflex sandwiched in between and in the joints sounds like a good solution.

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Old 08-02-2017, 04:09 PM   #7
1964 26' Overlander
Collingwood , Ontario
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so could you use Tempro 635? if so what kind of thinner and what proportions..thanks
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Old 08-02-2017, 09:35 PM   #8
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1979 23' Safari
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Black polyurethane roofing sealant would work too.

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