Personally, I would think about NOT painting it, if it has its original paint job, but that's just me. I love the old rustic look of found furniture. If you do want to paint it, though, and it's good enough not to have to sandblast it (i.e., it's really not that rusty), then you can use any of the good quality spray paints such as Krylon to paint it whatever color you want it. Most of these now have a primer built in. You'll want to first give it a good sanding w/ a coarsish paper and then a good follow on w/ a fine grit paper. Make sure it's good and clean and smooth and paint away--out in the yard and away from anything that can get oversprayed, of course. Keep it light and do several coats, rather than one thick coat. If the paint starts to run while you're painting, you're putting it on too thick. Better to spray lightly, let it dry and then repaint. Lowe's typically has a huge selection of spray paints in some really neat finishes. I painted an old grate w/ a kind of variegated finish and we used the same spray on our porch lights to make them blend in better. Worked great. Have fun. Please post when you have it finished.

Don't know if it has the same properties as the bondo but I use Minwax Wood filler. You can trim it down as it hardens so that there is minimal sanding needed after it cures. I've filled, primed and painted holes in 6x12's and afterward no one could spot the repairs. Here is a link that might be useful: wood filler

Thanks Hendricus, I thought about that approach, but the shims would be visible from the front. I thought about mitering that front edge at 45* and ripping down a long thin piece to cover the gap (kind of like you would do for a countertop), but not sure if I'll be able to do that kind of miter cut in tropical hardwood - I hear it's a bear to work with. Attaching that thin piece could be tricky as well.

I'm so glad you are wrong Sophie. The expert came today and man I'm now so relieved and can be excited again. He explained in detail to us all that he will be doing. Only thing he wants is the door off and will be put back on later. He showed the last ten he did just last month alone. In his 27 years has had only one he had to come back and fix that he did about 17 years ago, but he said the products now are so much better. He said it's a fantastic plan (and view