Body filler and primer calculator

How much filler to mix for the areas you're repairing, and how much primer to buy for the film build you want. The primer math uses the same physics paint makers use on their tech sheets.

Enter your numbers
Body filler
A 12 × 12 in patch is 144 sq in.
1/16 in is 0.0625.
Primer surfacer
Total across all coats.
On your product's tech sheet.
Roughly 65% for HVLP, lower for conventional guns.

Primer to buy

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Mixed, sprayable gallons.
Primer in quarts
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Body filler
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Filler volume
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Primer from film build

Gallons = area (sq ft) × dry mils ÷ (1,604 × volume solids × transfer efficiency)

One gallon of pure solids spread 1 mil (0.001 in) thick covers 1,604 square feet. That's simple geometry: 231 cubic inches in a gallon, divided by 0.001 in, divided by 144 square inches per square foot. Real primer is part solvent (volume solids tells you how much is left once it dries), and not all of the spray reaches the panel (transfer efficiency).

Filler

Quarts = area (sq in) × thickness (in) × (1 + waste) ÷ 57.75

A quart holds 57.75 cubic inches. Filler is sanded down heavily after it cures, so the waste allowance is larger than for paint.

Frequently asked questions

Why does the primer math use the same physics as paint makers?

Film build (how thick the coating actually goes on) depends on volume solids and transfer efficiency the same way for primer as it does for paint or clear coat — using the same physics-based approach that's already the industry standard just applied to primer's specific numbers.

What is transfer efficiency and why does it matter?

It's the percentage of sprayed material that actually lands and stays on the part rather than overspraying past it or bouncing off — a lower transfer efficiency means you need to buy noticeably more material to reach the same actual film thickness on the part.

How much filler should I mix at once?

Mix only what you can comfortably apply before it starts to set — filler working time is short, and mixing too much at once commonly leads to wasted, hardened material rather than genuinely saving time.

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