Bodywork
Wet Sanding
Wet sanding of paint and clearcoat for show-level correction · Pre-machine-polish prep
Issued April 2026 · Next review April 2027
At a glance
- Task / activity
- Bodywork Wet Sanding — paint / clearcoat correction
- Location
- Workshop / detailing bay (dry, well-lit, dust-controlled)
- Personnel required
- 1 trained detailer
- Estimated duration
- 4–12+ hours per vehicle (often runs into JSA 02 machine polishing)
- Prerequisite training
- Site induction · Machine polishing competency (JSA 02) · Wet-sanding technique sign-off · Electrical safety basics
What is this?
Wet sanding of clearcoat and paint to remove orange peel, sanding marks from prior bodywork, deep scratches and runs — for show-level paint correction. Always followed by JSA 02 (machine polishing) to refine the sanded finish back to gloss.
Performed by 1 trained detailer in the workshop. Multi-hour to multi-day work depending on vehicle and finish target.
What could hurt you?
- • Burn-through of clearcoat — irreversible paint damage, much higher consequence than JSA 06 headlight sanding.
- • Clearcoat / paint dust inhalation (slurry suppresses but not eliminates).
- • Skin sensitisation from cumulative slurry contact (paint solids, clearcoat oligomers).
- • Hand-arm vibration syndrome (HAVS) when DA wet sanding is sustained over multi-day jobs.
- • Electric shock from DA polisher in wet conditions.
Mandatory PPE
Sealed safety goggles, nitrile gloves, P2 half-face respirator, waterproof apron / shirt, hearing protection if DA exceeds 85 dB(A). Long sleeves to prevent slurry skin contact.
Wet sanding bodywork carries higher consequence than headlight wet sanding (JSA 06) — the panel is the customer's paint, not a $200 plastic lens.
STOP — Suppress dust at source AND check the panel before each pass
Always keep the panel wet — slurry contains the paint dust, dry sanding releases it. AND inspect the area you are about to sand for: existing thin clearcoat (visible peeling / pre-existing burn-through), edges and corners (always at risk), badges / mouldings (mask first), measurement-confirmed clearcoat thickness if a paint depth gauge is available. Burn-through on a customer panel is hours of refinishing work to fix and a hard conversation to have.
Mandatory PPE
-
Sealed safety goggles
AS/NZS 1337.1 — wet sanding mist + abrasive particulate. Sealed goggles, not open glasses.
-
Nitrile gloves
EN ISO 374 — protects from slurry contact (cumulative paint-solids exposure can sensitise).
-
Half-face P2 respirator
AS/NZS 1716 — paint / clearcoat dust is fine and respirable. Mandatory for sustained sanding even with wet suppression.
-
Waterproof apron + long sleeves
Wet sanding produces dirty slurry — skin protection plus easier clean-up. Long sleeves limit cumulative skin contact with paint solids.
-
Hearing protection
AS/NZS 1270 — required if DA polisher use exceeds 85 dB(A).
-
Non-slip safety footwear
AS/NZS 2210.3 — workshop default. Wet floor + electrical risk.
Procedure
- 1
Pre-inspect the panel under inspection lighting; identify burn-through risks (edges, corners, ridges, prior repair). If a paint depth gauge is available, measure baseline clearcoat thickness.
Hazards
- •Eye strain from inspection lights
- ⚠Misjudging clearcoat thickness — burn-through risk on subsequent steps
Controls
- •Use task-appropriate LED inspection lights, not bare bulbs
- ✓Document baseline thickness if measured — note any thin areas before sanding
- •If a paint depth gauge is not available, sand defensively — coarsest grit no lower than 2000, frequent inspection
- 2
Mask vulnerable edges, badges, mouldings, plastic trim with two layers of high-quality automotive masking tape.
Hazards
- •Burn-through on edges if masking misaligned
Controls
- •Two layers of tape on every edge / corner / ridge
- •Confirm coverage under inspection light before sanding
- 3
Inspect DA polisher / wet-sanding tool, cord and pad before use. Confirm interface pad is appropriate for paper grit.
Hazards
- ⚠Damaged cord — electric shock risk in wet sanding conditions
- •Loose pad — projectile risk
Controls
- ✓Visual check of cord, plug, casing; tag-out damaged tools, do NOT use
- ✓RCD-protected outlet mandatory for any corded tool over wet floor
- •Hand-tighten pad and confirm fully seated before powering on
- 4
Wet sand starting at the coarsest grit needed for the defect (typically 2000–3000 for clearcoat correction, 1500 only for severe defect). Step up grits in halves: 1500 → 2000 → 3000.
Hazards
- ⚠Burn-through on edges and clearcoat — irreversible paint damage
- ⚠Paint / clearcoat dust inhalation from slurry — fine respirable particulate
- •Cumulative skin contact with paint solids (sensitisation potential)
- •Slip on slurry runoff
- ⚠Electric shock — DA + wet floor + corded outlet
- •Repetitive wrist motion — strain over multi-day jobs
Controls
- ✓Keep panel WET at all times — re-spray surface immediately if drying
- ✓Do NOT sand directly on edges, ridges, corners — sand TOWARD them, lift before contact
- ✓Lower speed near corners; stop and inspect frequently
- •Sealed goggles + P2 respirator + nitrile gloves + waterproof apron
- •Towel down floor regularly; mop slips immediately
- •RCD-protected outlet for DA; coil cord up off the wet floor
- •Switch hands periodically; take micro-breaks; use lighter pressure not more time
- •Light pressure — let the paper do the work; pressing harder cuts faster but burns-through faster too
- 5
Inspect under LED light between grits. Check for any missed areas, premature breakthrough, or remaining defects.
Hazards
- •Eye strain
- ⚠Missing breakthrough until polished — by which point it is too late
Controls
- ✓Spray panel clean of slurry, dry with microfibre, inspect at multiple angles before stepping up grit
- •Photograph any concern area for the worker / lead to review
- •Stop and escalate to lead if any sign of breakthrough — better to halt now than after polishing
- 6
Final sand at finishing grit (2500–3000 typical) until the surface is uniformly hazed.
Hazards
- •Continued slurry exposure
- •Repetitive strain
Controls
- •PPE as step 4
- •Vary hands and posture
- 7
Clean panel of all slurry. Dry thoroughly. Hand off to JSA 02 (Machine Polishing) for refining sequence — the surface MUST be machine-polished before customer delivery.
Hazards
- •Cross-contamination of polishing pads if slurry residue left on panel
- ⚠Customer delivery without polishing = matte hazed paint, irreversible without further polishing
Controls
- ✓Vehicle does NOT leave the workshop until JSA 02 polishing is complete
- •Wipe down panel with detail spray + clean microfibre before commencing JSA 02
- •Worker who sanded should also polish (or hand-off documented clearly to next operator)
- 8
Dispose of slurry, used paper, contaminated water.
Hazards
- ⚠Paint / clearcoat slurry into stormwater
- •Sharp paper edges
Controls
- ✓Catch slurry in tray; bin with general waste — never to drain. Council trade-waste compliance.
- •Bag used paper in sealed bag
- •Wipe down work area; coil cords loosely