Plastic Repair

Recent progress on Ella has been slow, as usual, but I figure if it hasn't come to a complete halt, then everything is ok ;-).

The top-end machine work is done and should be shipped back from Rennsport Systems next week.  They also are doing a distributor rebuild for me.

I also shipped out my mufflers for a Fister Stage 3 conversion and ceramic coat -- I can't wait to see how they look and even more how they sound!

That stuff will all be back before I am ready to start re-assembly -- the list of "while I'm in there" tasks to do is still long.  One item on that list was repairing a cracked plastic wheel liner and a broken under-body tray.

The under-body tray (Porsche part number 99350412900) was functional and out of sight, so I couldn't justify the $300 to replace it.  However, I also didn't like it being broken.  Last year I fixed my kids' plastic slide using fiberglass tape and plastic epoxy, and I figured the same would work on this part.  Here are a few before and after photos.

It's not hard to see how this piece broke off.

The process is pretty straightforward:

1. Drill a small hole at the end of every crack to keep it from spreading.
2. Create a "v" shaped channel along every crack to provide space for the epoxy.
3. Rough up the surfaces to be coated with epoxy/fiberglass tape with 220 grit sandpaper.
4. Apply fiberglass tape. I used drywall joint tape with adhesive. I used (Amazon affiliate link) Ultra Thin Drywall Tape, 2-Inch by 300-Feet, White.
5. Apply plastic epoxy - I used the 20 minute set time version from Loctite, available at Lowe's or Amazon (affiliate link) Loctite plastic epoxy.
6. Apply additional layers as necessary, roughing up the surface between each layer.
7. Sand/polish to suit your desire.

Since these parts are out of sight, I didn't try too hard to make it perfect.  Next time though, I would try dying the epoxy black to match the plastic.  

The repair feels very sturdy, although I didn't stress test it...