Hard box repair

As suggested I'm starting a new thread on my boxes repairs. Last night I was able to use my heat gun to get the cracks to match. There is a gap where the plastic shrank on the bottom. That will be covered with fiber glass. I'm heading to Depot for supplies.












It will take another cleaning and light sanding to rough up so it will stick.
Steve

I was under the impression that fiberglass resin does not stick to PVC or ABS. HOWEVER Home Depot has all kinds of solvent plumbing glues that's perfect for that.
Also you can buy thin sheets of PVC and ABS from McMaster Carr or hobby shops.... form them with your heat gun to fit inside the cases for stiffness over those cracks and use that same solvent glue.
I have repaired a few PVC fairings in this manner, sanded the outside, used filler primer, sanded flat and smooth ... Repaint with rattle cans paints and they look great.

I don't see why it wouldn't. I'll try the lid on the other box. If it doesn't stick, then I'll have to do what you suggested.




Maybe use ABS glue with the fiber glass sheets?
Steve

I really like this stuff, 4 years, somewhere around 35,000 miles and no trouble.



a hot glue gun does a good job of tacking pieces together

Basic fiberglass resin and fiberglass cloth! They sell kits at all the auto parts stores.
I have this 25 year old gallon of Dyna Hair, fiberglass, reinforced stuff!
Gonna finish my 3 piece fender one of these days!

I've used the ABS cement (nasty stuff!), some ABS sheet and a heat gun (to shape the sheets) to repair KZP cases. It works, but it certainly isn't the prettiest. If all you have is cracks and no missing bits, the ABS cement alone can repair it.

One of my cases was coated on the interior with fiberglass by a PO. It is way sturdier than the pure ABS cases and has never cracked, broken, or deformed. I guess that's anecdotal evidence that fiberglass will stick to ABS.

So I'd say fiberglass is the way to go for a good looking and durable repair. It sure is messy to work with though.

After cleaning with thinner, I roughed up the areas with #100 and #80 paper.




For those that haven't done this before, you fold the paper in half. Fold it back and forth a few times so it will tear easily at the seams.


Fold it again to make 1/4 sheets. They will now fit a sander, sanding block or fold it again to make hand sanding easier.
.

Clean again.


Brushed the thinner and it became like glue. Time to apply the first course of fiber glass.


It'll stick.




Got in the corners.


Now to let it cure and apply another course.
Steve

Second course of glass and started on the hinges. Tomorrow I start on the outside. :whistle:
Steve

I was half joking when I suggested a write up but this is really interesting. I imagine the finished product will hold up well so you can use that insurance money elsewhere.

Thanks for the suggestion. That's what these threads are for. If someone needed advice on fixing a cracked or mangled hard box, they would never find it in the close call thread. It's holding together fine. When I made the initial call, I was told I could take it to a body shop, buy new ones, do it myself and spend the money any way I want. :whistle: I just won a Mustang LTD seat and am picking up other little things I needed. More to come. :woohoo:
Steve

Now just keep a close eye on those Bozos out there so it doesn't happen again. By the way, nice work.

A little light sanding tomorrow and I can paint them. Even fixed some cracks on the other box.


I could spend more time on them and maybe I will later. Have some business to attend to 400 miles away. Need the boxes and a few other things done to do it.
Steve