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Old 08-06-2011, 09:54 AM   #1
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1996 34' Excella
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Need help with Interior End Caps

Hi , Both of my interior endcaps are cracking around the corners of the cabinets. The rear being the worst as it appears to be load bearing but I don`t have anything in them although the breaker box is in one side but it is fastened to the wall. The weight of the wooden doors could be causing the cracks but I am not sure.Also the area just above the cabinet doors in the rear seems to be seperating on top possibly heat related. Any one else experiencing this ? And what would be the best solution ?
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Old 08-06-2011, 11:45 AM   #2
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Any ideas
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Old 08-06-2011, 12:15 PM   #3
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My best guess is your running gear is un balanced and the vibration is causing the cracks. Do you have any loose rivets on the inside (black circles around the rivets), or rivets that have fallen out?
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Old 08-06-2011, 01:30 PM   #4
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No rivets are missing. I replaced the tires,and shocks 2 yrs ago and they probably have less than 1000 miles on them.
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Old 08-06-2011, 02:10 PM   #5
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Davis, those cracks seem to be common to many. Probably some age, vibrations, terrible roads, just one of those AS things. Try drilling a small hole, maybe 1/8'', at the end of the crack. May at least stop it. John
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Old 08-06-2011, 07:19 PM   #6
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What about the last picture with the long gap beside the cabinet door, it seems loose there. Do you think I could put a bead of liquid nails there so it wont keep pulling apart ?
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Old 08-07-2011, 09:09 AM   #7
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Davis, inside the cabinet, at the crack, should be a plywood partition that is the end of the cabinet. Removing it should allow access to the back of the crack. Might apply a fiber glass "patch" over the length of the crack, on the inside. Kits are available auto parts stores & home centers. This should stabilize the crack. Then the outside cosmetics might be done with 5 minute epoxy, then color in with paint & artist brush once dry. Fiberglass & epoxy are handy stuff to have around. Practice first. john
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Old 08-07-2011, 08:17 PM   #8
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Quote:
Originally Posted by sandlapper View Post
Davis, inside the cabinet, at the crack, should be a plywood partition that is the end of the cabinet. Removing it should allow access to the back of the crack. Might apply a fiber glass "patch" over the length of the crack, on the inside. Kits are available auto parts stores & home centers. This should stabilize the crack. Then the outside cosmetics might be done with 5 minute epoxy, then color in with paint & artist brush once dry. Fiberglass & epoxy are handy stuff to have around. Practice first. john

Thanks . That sounds like a plan. And maybe I can figure out if extra support can be added as well inside the endcap to the alum. wall.
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Old 09-08-2011, 07:46 PM   #9
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Find some pieces of ABS, preferably white, a quart of MEK solvent, a metal 1 quart paint tin with tight lid and some fiberglass cloth.

Put a handfull of the ABS pieces in the Tin, and pour in a small amout of MEK. Seal the lid and leave for a few hours.
The MEK will melt the ABS, and form a paste. Adjust the amount of ABS or MEK to get a good consistancy.

Put a layer of Scotch tape on the visible side of the crack, and brush or squeeze the paste into the crack from behind.

The MEK in the paste will melt and fuse the 2 sides of the crack, and fill the void. Leave it to set, which may take several hours.
When it is hard, you can brush another coat of the paste on for strength, or even back it with Fiberglass.

Here is a spare wheel cover I repaired using the same method.


Here is how the MEK/ABS Paste looks.


Road worn corner..


Rebuilt..


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Old 09-08-2011, 07:51 PM   #10
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Then I taped it over to hold the corner..


Later I reinforced a cracked corner with the Paste and Fiberglass.



Forgot to take a pic when it was all wetted out and trimmed, but its strong now!
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Old 03-08-2012, 12:27 AM   #11
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I have several cracks in both end caps.

When I was going through Harbor Freight today, I saw a kit to weld plastic - so I bought it. There are three types of welding rods depending on what type of plastic you are going to weld. What type of plastic is used for the interior end caps?
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Old 04-06-2012, 07:25 PM   #12
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Thumbs up thanks again Keyair

im ready to start my abs plastic fix on my tyre cover as well and stumbled across your pics...thanks a billion Keyair, you make it look so easy

i'm guessing the interior endcaps are very similar to fix.....i'm ripping the rear one out this weekend
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