Repainting the 4Runner Fiberglass Shell: The $50 Paint Job Way

This is less of an instructional, and more of a "ehhh, it looks better than it did."

Using the $50 Paint Job as a rough guideline, I set out to make my 4Runner's fiberglass shell look better than this. Duct tape stains, chips, faded factory paint, she had it all.

Fiberglass shell before

2 Coats primed, with 300 grit inbetween

I opted to move the shell into the garage to protect from weather, and to reach the center of the roof better.

Start by sanding shell with 150 grit to knock down blatant imperfections. Wipe with damp (water) cloth, then hit with 300 grit. Wipe with mineral spirits and let dry.

Take a can of Rust-oleum filler primer and apply your first coat. 

Smooth as silk after primer and sanding

I sanded with 300 grit between primer coats, and lightly used 600 grit after my final primer coat. I applied 4 or 5 primer coats total to help fill in the trail scratches and chips. The primer will be very dusty, and I highly recommend a breathing mask. Ideally, remove dust from sanding with compressed air.

First coat of Rust-oleum Black Satin Enamel

For paint, I used Rust-oleum Satin Enamel in the can, with foam rollers, and foam brushes. The brushes are almost pointless, but get one or two for getting around the drip-guides of the fiberglass shell.

I cut my enamel 50/50 with mineral spirits. This is thicker than $50 Dollar Paint Job, but I found with thicker paint, I got less roller marks. 

Two coats paint, then wet sand

After two coats, I began sanding with wet sand paper. I used 600 grit, soaked 15-minutes in water, then sanded with a spray bottle of water to keep everything well-lubricated.

In the Texas heat, I was able to apply about 3 coats per day. Typically 2 coats will be the daily maximum.

Four coats paint, getting ready for 1000-1500 grit wet sand

I cleaned my paint with mineral spirits after sanding. Reading back, this is apparently unadvised, as it can eat the paint. I personally didn't notice a problem.

After 2 coats I used 600 grit, after 4 coats I used 1000, 5th coat I used 1500, 6th coat I used 2000 grit. I had the grand plan of polishing with compound, but it honestly looked good the way it was.

Six coats paint and 2000 grit wet sanded.

In retrospect, the satin finish was probably the best finish I could have picked. Flat eventually absorbs moisture, and gloss would have been very hard to work with and smooth out. I would 100% recommend satin for this model of 4Runner shell.

Then apply liberally with grit and mud 

On the plus side, the satin finish cleans up great with a pressure washer

Good info from the pros:

• Cleaning between coats