Burnt through a door skin yesterday with my DA sander

I was smoothing out some filler on a 2018 Civic in Omaha and got too aggressive with 80 grit, now I have a paper-thin spot near the handle. Anyone else have a trick for saving a panel after you've sanded too deep?

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davis.mia3mo ago

Keep feathering it out with 320 grit on a block so you don't bite through even more. Once you're through the clear, hit that thin spot with a skim coat of glaze putty and let it dry before sanding again with 180. I've saved panels worse than that on old Honda doors, just go slow and check it with your fingers every few passes. You can also use a stiff plastic card to feel for the low spots before you blast through any more material.

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jason_stone3mo ago

Man that "check it with your fingers every few passes" tip is gold. I learned that the hard way after burning through the clear on a fender and had to start mixing paint that didn't match right. Your glaze putty trick is solid too, especially when you think you're about to sand through into metal. Last summer I was fixing a dent on my neighbor's old Civic door and used pretty much this exact method - 320 on a block, felt for the high spots with a plastic card, skim coated the thin areas, and it came out smooth as glass. Just takes patience and a light touch, like you said.

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