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Great Post
I also restore cars for a living and am of course involved in this stuff on a day to day basis as well-this is absolutely the best treatise I have read on fillers. I back up all of what you say.
Thank you very much for writing it, its very informative and well written.
I cannot count the amount of times people "want lead" only because its what they heard was best.
Ditto for the thread on paint. I always get the "how many coats of paint" question.
To backup what you say on the importance you stress on proper preparation:
I have painted things with catalyzed and reduced rustoleum shot out of an old spray gun and have
a.) had people not believe it was rustoleum
b.) had it last for years and years with great gloss retention on a non-garaged daily driver here in New England-so it gets beat up.
Of course the prep was critical, and the wetsanding and buffing made it like glass. It was a shade more gray than the body of the car-which was black, but this was not noticeable because the part is so separated from the body. It was also much smoother than the factory finish so the owner was very happy with it.
It was a black spare tire cover for a MB Galeandewagen.
As a tip for anyone wanting to try this, I reduced it about 4:1:1 with enamel reducer (generic stuff I had around) and enamel alkyd hardner from Glasurit's inexpensive Limco line-only because it was what I had around after painting some TV ad backdrops in acrylic enamel and the job was done free as a favor to a good friend.
It also works great for suspension parts-but I always spray over epoxy or self etching primer.
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