Bondo Body Filler Casting

bondo body filler is normally used to fix dents in cars and trucks but A can use it for making small plastic like parts pieces or toys ill show you how to cast bondo in a one time use plaster mold for bondo

Step 1: Supplys Tools

stuff you need to cast bondo

Step 2: Wax Part 1

you need a chunk of wax and the small knife carve out the part you need to cast in bondo sorry for the low quality but this is the piece made of wax

Step 3: Plaster Part 1

ok now your going to fill the canister with plaster around the wax

Step 4: Wax Part 2

now the plaster is dry chip of the lare on top of the wax then make a funnel like shape on top of the plaster with a knife thin melt out the wax I'm the microwave

Step 5: Bondo

ok now mix the bondo and smear it in the cavity in the plaster left from the wax tap it sow there aren't air pockets

die yo-gi-oh you wasted my life


Step 6: The Brake

now that he bondo is hardend its time to brake off the plaster water helps a bit but it only takes a minute to scrap it off with a knife and then all you need to do is trim up the sides on it and your done



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    11 Discussions

    DR Mac

    10 years ago on Introduction

    Hi, I've done something similar a few times, try mixing your "Bondo" etc 50/50 with polyester (fiberglass) resin, It pours easier and the stuff I had made the castings incredibly tough! You can also get other types of body filler in various shades including white. I colour mine with bottled pigments for fiberglass. Keep experimenting and have fun! Hope this helps.

    1 reply
    DarkalityLDR Mac

    Reply 3 years ago on Introduction

    have to be careful with fiberglass resins because they're prone to shrinking as they dry. not a problem for most things, but the shrinking is uneven and can mutilate fine details.
    As a radical side note, the addition of glow pigment to fiberglass resin is always good fun. To get it on the cheap, purchase glow paint from the crafts section of walmart and paint it onto plexiglass and scrape & grind it when it dries. the liquid form will prolong the resin hardening.


    10 years ago on Introduction

    I have been making small carvings out of vegetable ivory nuts. The two problems they have, besides being only about plum size, is that they have a dime sized void in the center, and since they are nuts after all, they have an empbryonic palm tree at one end, that falls out when they dry out, and leave a hole about 3 milimeters wide by 3 milimeters deep. I wonder if bondo would fill that hole without looking out of place. The ivory nuts are usually a pale yellow-white.

    3 replies

    Reply 7 years ago on Introduction

    With the Tagua nuts I think you'd be better off starting with a white casting resin like Snap-On and adding a little yellow pigment to match the cream of the nut than using Bondo.


    9 years ago on Step 6

    for the love of freaking pete, either use a macro lens or hold the object further!!!! You can't see anything in these pictures!!!!!


    10 years ago on Introduction

    Hi Brandon. Your instructibles are getting better. I have used bondo to copy small pieces of wood trim.


    10 years ago on Introduction

    Nice work. Simple and to the point. Is this a common method, as I have not read of it before?