Repairing Clear-Coat Burn-Through: Respray Blending and Micro-Sanding Fixes (800–3000 Grit Guide)

Clear-coat burn-through happens when sanding or polishing cuts through the top layer, exposing base color or primer. It’s one of the most dreaded finish mistakes—but it’s fixable. With careful micro-sanding, feather-edge blending, and localized respray, you can restore seamless gloss without refinishing the whole panel.

Why Burn-Through Occurs

Most clear films are only 40–60 µm thick. Aggressive pressure, dull paper, or lingering too long on edges removes that protection fast. Once the base color shows, the only cure is adding material back—but the surrounding blend must stay invisible under light reflection.

Recommended Tools

• Soft foam interface pad and mini sanding block.
• Wet/dry sandpaper (800–3000 grit).
• Pre-tack cleaner and lint-free wipes.
• Matching 2K clear or spot-repair aerosol system.
• Dual-action polisher and fine compound.

Best Grit Sequence for Repair

• 800 grit – levels feather edge before new clear.
• 1500 grit – smooths blend zone after cure.
• 2000 grit – removes minor orange-peel texture.
• 3000 grit – final polish prep before buffing.

Step-by-Step : Localized Burn-Through Repair

1. Identify damage. Look for dull halo or exposed color—edges usually reveal thin spots first.
2. Feather-sand perimeter. Wet-sand with 800 grit in small arcs around the spot, easing into sound clear; aim for a 1-inch fade-out zone.
3. Clean and mask. Degrease with tack wipe; mask 4–6 in around the blend to prevent overspray ridge.
4. Respray clear. Apply two light coats, letting each flash per manufacturer spec. Extend the second coat slightly beyond the first for feather overlap.
5. Allow full cure. Wait 24–48 h (longer for 2K systems) before sanding again.
6. Micro-sand the blend. Start with 1500 grit, then 2000 → 3000 to level overspray edge until transition disappears under light.
7. Buff and inspect. Use fine compound and low RPM until reflection matches adjacent area.

Special Cases

On metallic bases, never expose pigment—mask edges tightly and mist extra clear overlap. For single-stage finishes, color sand the repair with 2000 grit and polish directly—no separate clear required. Always blend with the curve of the panel to keep reflections natural.

Pro Tips

• Use fresh paper—dull grit heats and thins faster.
• Keep edges taped during early grits; remove tape only for final blending.
• Warm panels slightly (not hot) before respray for better flow-in at the feather edge.

Aftercare

• Do not wax repaired area for 30 days; let solvents outgas fully.
• Wash only with mild soap for first week.
• Rebuff lightly after one week to unify gloss if halo reappears.

FAQs

• Can I fix burn-through without re-clearing? Only if color isn’t exposed—light haze can be polished out; bare base must be recoated.
• Why does new clear look thicker? Slight overlap builds film; final wet-sand and buff will flatten it visually.
• Can I spray just a spot? Yes—use blending solvent to melt edge; sand and polish after full cure.

Watch & Learn

Keep repair materials ready: stock fine, super-fine, and ultra-fine 25-sheet packs to micro-sand blends safely and restore perfect gloss after clear-coat burn-through.