A while ago I sent my stripped full-frame-off van off to the professional paint shop to have it:
Zinc thermal sprayed
The car was in perfect condition with no rust and panel damages whatsoever. Because the van is 35 years old (40000 mi original) and I want to keep it the next 30 years as a daily driver I wanted to treat it with the best solution incl sandblasting in the appropriate areas, zinc thermal spraying for maximum corrosion protection and onwards with a 2K epoxy primer, paint and clear coat. I made my research and settled for the best professional painter (I believed) who offers both blasting, spraying and painting in the same shop. Of course we agreed on the fact that blasting and spraying could only be performed on the strong parts of the panels: Weak, large areas would only be sanded before being primed and would thus not offer the same corrosion protection.
Now fast forwarding and to make a long story short:
I pulled the car out of the project from the paint shop because they had done so much damage to the body that I couldn't stand it anymore. They had no clue what they were doing and I discovered errors each time I visited them.
I delivered a van in perfect condition with absolutely no required body work, and this is the result I got back (blasted, thermal sprayed, primed + lots of bondo):
I have 2 major issues:
a. They sanded (not blasting and not spraying) the roof with a power sander without the arch supports with the result that the roof turned into a bath tub (literally). After the pop-up of the roof, the sheet metal is now wobbly and destabilized. I believe that the mechanical pressure coupled with the heat generated by the sanding process made the roof wobbly. It is evident that the panel has been stretched a bit across the width of the van.
A video of the situation:
b. As an error they used 1mm steel grit (with a very high density) and sand blasted the panels from the inside out resulting in panel bulges below the windows. Originally we agreed that the van floor had to be blasted and thermal sprayed and during that process the blaster hit the weak panel from the inside resulting in inward bulges below the windows. Without consulting me, they covered up the mess with 5mm (almost 1/4 inch) bondo.
A video of the situation:
Question: Can anyone guide me in a direction on how to fix these problems? I need to know something about these processes on how to fix it. At the moment I feel I cannot trust any painter or body work shop due to the fear of even more damage. I did my homework in choosing the right place, but ultimately it failed anyway.