Since Corvette bodies are made of a different material than most other production cars, repairing minor damage can require alternative materials and techniques. While fiberglass and SMC (Sheet Molded Compound, which is found on later models) have the advantage of being rustproof, such composites are subject to their own sets of problems. These range from crazing (also called "spider webbing") to cracking, usually from a slight impact. More-severe or widespread body damage may require the complete replacement of large components-a job best left to a pro-so we'll limit our focus to minor damage that can be repaired right in your own driveway.
We'll start with slight surface imperfections. If polishing and waxing isn't producing the smooth finish you'd like to see on your beloved Corvette, consider using 3M Scratch Remover, which is designed to minimize defects that don't penetrate the clearcoat (assuming your vehicle has a two-part urethane paint). This product is fairly simple to use, requiring only three separate steps and a common household drill. We tried the 3M product on a C5 that had a few scratches on it, and they all but disappeared.
For cracks or crazing (the latter is usually seen on older fiberglass bodies), a type of adhesive called Plastex can repair a wide range of materials. In addition to fixing fiberglass or SMC, it can be used to fabricate small components, or even repair metal (using a slightly different version of the repair kit).
The inventor of Plastex, Tim Lewis of G.T. Motorsports, has some pretty impressive credentials in chemical engineering. In addition to being trained at the Northrop Institute of Technology, he's worked on the adhesive tiles used on NASA's space shuttle, and he served as manager of Harrah's car collection. So he knows his way around composite materials and how to take care of fine automobiles.
Using Plastex is a straightforward process, easier than working with resin and fiberglass. Unlike conventional resin and catalyst, for most repairs the mixing ratio doesn't have to be in precise proportions, as long as the powder is thoroughly saturated. Depending on the type of damage, Plastex powder can be used with or without the cloth included in the kit. It dries very quickly in a variety of weather conditions, so you can sand it and prep for paint in short order.
Fine scratches in the clearcoat...
Fine scratches in the clearcoat can make your Corvette's finish look like a road map. If buffing and polishing doesn't get them out, a more intensive approach might work-as long as the scratches don't penetrate to the color coat. A quick way to evaluate the depth of the scratch is to run your fingernail over it. If you can feel the scratch, but your fingernail doesn't catch, you can probably repair the damage with 3M Scratch Remover.
The 3M Scratch Removal System...
The 3M Scratch Removal System is a simple kit, consisting of a small abrasive pad, a buffing wheel, two polishing pads (one coarse, the other soft), and two 1-ounce packets (Rubbing Compound and Scratch Remover). Look closely, and you can spot the small white scratch between the two pads. John Balentine, who volunteered his C5 for this project, says his dog Missy was the culprit. (She isn't allowed in the garage anymore.)
After washing the affected...
After washing the affected area with soap and water, spray water on both the finish and the abrasive pad.
Even though the 3,000-grit...
Even though the 3,000-grit pad feels soft, rub gently on the scratch until a bit of foam appears. After about 10 seconds of rubbing, wipe off the slurry with a wet paper towel to see if the scratch has disappeared. Don't overdo it, as the clearcoat is not very thick.
The area being rubbed will...
The area being rubbed will dull slightly, depending on the angle of the light. The following steps will eliminate this discoloration.
Insert the buffing wheel into...
Insert the buffing wheel into a standard household drill (note that a variable-speed trigger makes it easier to control the speed of the buffing wheel, as it's important not to let it heat up). Next, squeeze a dab of 3M Rubbing Compound on the pad. To prevent splatter, smear the compound around manually before starting the drill.