The first coat of Bondo can be leveled with a DA sander. Subsequent coats, (and there WILL be subsequent coats), can be leveled with an air file. Final coats need to be done the old fashioned way, by hand with a sanding board long enough to cover the entire area.
When you think you have it level, prime it and apply one or more coats of spot putty. The spot putty will fill minor imperfections and sand scratches. You may have to apply several coats of spot putty, using increasingly finer sand paper.
Then build up several coats of primer and sand again. By the time you're ready for the finish coat, you'll be up to 600 to 1,000 grit paper.
Keep in mind automotive finishes are contrary by nature. They just love to show off sand scratches and imperfections when you thought you had perfection.
It's a painstaking and time-consuming process, but after 30 years of involvement if there are any shortcuts, I've never found them.
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Today's Featured Article - New Life for an Old Allis - by Tyler Woods. My friend Jon, has an old '39 Allis Chalmers B. He thought it a marginal tractor that had long since served its time. She smoked terribly and never had much power but he couldn't afford another so he was limping along with what he had. Jon's Allis has a small front loader and though it doesn't carry much, it serves his needs. It was the hard starting and low power that made him think it was time to replace the old girl. Jon called me to help him discover why his tractor wouldn't start
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