Originally Posted by dougjamie
......We're trying to think outside the box on this but we're coming up blank so far. Any ideas would be appreciated.
First - stop drill the end point of any cracks to prevent them from propagating.
I had a severe crack on the bottom of the shelf of the '78 Sovereign
- just under the right tambour door as per your photograph.
The plastic (or ABS) is about 3/32" thick - what I did was to cut a piece of 3/4" Western Cedar (or any light easily workable and tough wood that takes screws readily without splitting) and secured it behind the crack. You may need to place several individual wooden backer pieces since your crack is in a compound curve.
I drilled and countersunk screws about 1" apart along either side of the crack, "bondoed" and sanded the entire area.
Since my endcaps had taken on a 1950's "pink" highlight, the plan from the getgo was to change the color of the endcaps.
I taped off the areas with 3-M 2" painters tape (brand dedication is important here - for some reason the 3-M (Blue) brand is far superior to any other I have tried) and sprayed on a light coat of "Krylon" Fusion as a primer (dries real quick - like 15 minutes or so) - the Krylon did not require the plastic to be sanded - just clean.
I then hit the primer with a heavy coat of Rustoleum Epoxy Appliance paint (I used a beige color).
I completed the whole thing - brought the crack together with the wood backer, bondo, primer, and cover coat - Sunday afternoon.
I used two colors of Krylon Fusion to "try" the colors - bright white and off white - neither "caught my eye" as well as the Beige Rustoleum. I really had planned to go with a bright white on the endcaps, but it just did not look "right".
We had excellent drying conditions all day Sunday and Monday, but when I checked the interior Monday evening the off-gas odor was still pretty intense. Be sure to use some kind of breathing protection.
The endcap repair and repaint was cheap, went on easy, it looks good, and it should last a long time.
Cheap, easy, looks good, lasts a long time......sounds like a relationship.