Originally Posted by 68 TWind
I have had good results on plastic repair in my 68 using fiberglass cloth and West System Epoxy as the resin rather than the usual polyester resin that comes in the fiberglass kits. If you just have a gouge or small hole you can make a mixture of the resin and microballon filler ( to the consistency of peanut butter) and patch the holes. I have found that this is a much better fix that bondo. West has a good web site (Epoxy by the Leading Epoxy Manufacturer | WEST SYSTEM Epoxy
) and there are also a lot of videos on Youtube on how to repair stuff with epoxy and fiberglass. Might be worth a try before going to all the trouble and expense of endcap removal.
1960's endcaps were heavy (in the good way), durable fiberglass. The ones in my Trade Wind still look great.
The ones in my 1983 Excella are made from thin plastic, about 0.050-0.060 (< 1/16) inch thick, measured with a dial caliper at a crack near the center top in the front cap. The 15" long crack in the rear cap shows it to be a little thicker, 0.085.
The plastic caps are a very different story from the fiberglass ones. Not an improvement by any stretch of the imagination. You can make patches using 'glass, but the parent material is still going to be thinner and more brittle than a cheap toy car.
68T Winds results will always be better and longer lasting on the fiberglass caps. If I ever have the caps out of my Excella, I will use them to make a mold and build fiberglass replacements rather than repair and cross my fingers. Too many other things in line ahead of that, though.