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Old 04-14-2015, 12:49 PM   #1
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1994 30' Excella
Winston-Salem , North Carolina
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Cracked Rear End Cap

1994 31' Excella 1000 Classic. The rear plastic end cap started a crack some time ago in the top corner of the wooden cabinet facing. It has now grown until that side is sagging and looks like it is in danger of eventually breaking loose. Any suggestions on how to repair? Looks like I need to remove the wood and see how to reinforce/repair. Thanks.
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Old 04-14-2015, 04:33 PM   #2
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Got a picture you can post?
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Old 04-28-2015, 09:51 AM   #3
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1994 30' Excella
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Old 04-28-2015, 11:53 AM   #4
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I know they make two part resins for plastic. You can buy them at auto parts stores. It would be best if you can get behind it and some how reenforce it. Can you pull that cabinet out?
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Old 04-29-2015, 07:46 AM   #5
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I looked yesterday and it appears that it can be unscrewed from inside. I am going to tackle it today. My electrical is inside one of them and might have to come out also, but Airstreamers have no fear 😎
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Old 04-29-2015, 09:03 AM   #6
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You can do it!!
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Old 04-29-2015, 12:40 PM   #7
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OK, got the cabinet doors off and it actually appears that without destroying the cabinets themselves ( plywood sides basically stapled to an aluminum pan there is no convenient way to expose the inside of the corner cracks, and yes, there are cracks on all four corners. Soooo, gonna see how good the two part epoxy is...Click image for larger version

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Old 04-29-2015, 12:52 PM   #8
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I will follow this with interest. My front cap has a similar crack that I want to repair. Let us know how the epoxy works.

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Old 04-29-2015, 02:18 PM   #9
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Well, done. Not perfect since the cap is flimsy and it is difficult to line up the edges of the crack. But will see how it holds. The end cap cracks because of the crappy way the cabinet weight is distributed. If it cracks again I will beef up how the weight is suspended. I did add some additional aluminum angle on the inside where the facing attaches. May or may not help, we shall see 😎Click image for larger version

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Old 04-29-2015, 02:55 PM   #10
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My solution to my '96 when it finally happens is to make up some wood trim to cover the crack. This seems to be a common occurrence since the factory decided to do away with Tambour doors

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Old 05-05-2015, 06:12 AM   #11
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OK, first run since the "repair"... After a couple of hundred miles of lousy interstate ( bumpy, pot holes ) we get to our campsite. Yep, the cabinet facing is on the bed, shaken completely loose. Obviously needed to use longer screws instead of the originals. Will beef up significantly to see if it helps. Going to loosen up the chains on the Reese a link also. Way too much stiffness apparently, too much bouncing going on. AS techs say axles are good, so ?
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Old 05-05-2015, 09:08 PM   #12
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Did the glue hold up pretty good?
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Old 05-05-2015, 09:45 PM   #13
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Definitely interested to see how the epoxy held up, what type did you use.

I had my end caps out last summer/fall. Got the rear back in (bath no cabinet) as a close out for work for the year. Still working on the front. Both had lots of cracks predominantly along the arch where they attach to the ceiling. I cut some strips of aluminum(~2" wide) and epoxied the strips along the back along the whole length from end to end behind the rivet holes, which is where the cracks were, to reinforce the crappy brittle plastic.
AS engineers ( if they exist) really need to get some rib's behind the end caps to support the cabinets weight. As an engineer, taking apart my '74 I was constantly saying to myself "what were they thinking".
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Old 05-05-2015, 11:07 PM   #14
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Weight and cost?
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