Quote:
Originally Posted by AlwaysTinkering
Good to keep in mind while working with it.
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The challenges of this project were.
I was unable to find a replacement cap.
I thought about an insurance claim but decided to see if I could fix it.
I did not want to try and take off the cap (I was afraid doing so would cause even more damage)
So repairs needed to be done using just the access the hole (from the damage)provided.
I wanted to try and have the resulting repair look fairly decent..and not just slap ”roofing” tape on it.
I was unable to find any reference to what I wanted to do….sooo I took what I did find for other ABS repair projects and adapted them for my solution.
First issue was how to bond everything together.
I found (on Youtube) a way of making ABS paste using Acetone and ABS chips. The material used in the Youtube video was black ABS.
My project was white. The only source I could find for White ABS was filament used in 3D printers (picture included)
I cut up the “filiment” into small pieces and placed them in a glass jar with a little Acetone. The next day I had my paste.
I used a Dremel with a wire brush attachment and cleaned up the work area.
I had three tears along with the hole I needed to repair. I drilled small holes into the RV cap at the termination point of each tear (doing this will keep the tear from continuing)
I then used straight Acetone and using a small hobby paint brush, I cleaned up the working area…this cleaning process also softened the cracks I wanted to re-connect.
I applied a layer of the “paste” to the cracks and clamped it together. (picture included)
I then applied more paste to the back side of the crack (going in through the remaining hole).
To reinforce the work area, I cut up aluminum mesh (into rectangles) part of a (drywall) hole repair kit. (pIcture included)
Slapped in more paste to the inside work area and applied the mesh pieces. I then covered the mesh with more paste so when the paste hardened it would all be bonded together.
I let the project cure overnight.
The next day I added additional aluminum mesh rectangles attaching them to the inside of the hole with the paste.
I was going to use it marine epoxy for the hole repair, but the ABS paste was working very well. So I filled in the hole with paste, let it cure then sanded it down with 600 grit (wet sand paper, then 800 then finished with 1500 grit (all done while keeping the area wet).
I have included pictures of the results. It is far from perfect. But a far sight better than it was. (Your opinion may differ).
ABS filament - $18
Acetone - $9
Hobby paint brushes $4
Note: I have practically a whole spool of the 3d printing material left over. Wish I could have found a less wasteful source for “white” ABS.
Now to get on the road and find out if it will hold up. Fingers crossed.