Every version of the Chevrolet Corvette has been made either of fiberglass or some type of plastic since it was introduced in 1954. The great thing about this fiberglass construction is that when a fiberglass Corvette body panel gets damaged, it is relatively easy to fix with parts that can all be purchased from your local auto parts store.
If the damage to the body is a stress crack, use a saw to cut along the crack. This will relieve pressure on the area. If this is not done, and there is still pressure on the crack, the damage may reappear after the repair. Grind and sand the edge of the crack down to a sharp edge on every edge that is cracked. Get the surface as flat and smooth as possible to avoid air gaps that will create problems later on.
Mix the two-part resin. Once it is mixed, it will begin to harden, so do not do this until the area is fully prepped. Mix small amounts as you go. Cut a piece of fiberglass mat the proper size for the repair. Soak the mat in the resin mixture and place the mat on the top of the repair. Use a roller to level the mat and to get rid of any air bubbles. Using the same method, add a piece of cut mat to the backside of the repair. The two pieces of mat should begin to bind together. Repeat this process until the damaged surface is built up to at least the level of the undamaged surface. Note: Use some type of mask to avoid inhaling the small pieces fiberglass that may float into the air during this procedure.
Shape the surface to the correct contour with a block hand sander and a dremel. Use the block sander for larger surfaces and the dremel to smooth out and shape tighter areas. Be careful during this process, since you are trying to make the body look like it did when it left the factory.
Mix the two-part body filler, which is made of bondo and a small amount of hardener. Apply the filler to the surface of the fiberglass. Make sure the layer is as thin as possible. Let the filler harden. Once it has dried and hardened (usually about 15 minutes) sand the surface to match the contour and height of the adjoining surface. Repeat until you are satisfied that the surface looks right. Once this is completed, spray primer and paint over the area.
