Originally Posted by drjudy
Our endcaps are cracking pretty bad.
Are you saying the plastic is cracked? Ours are cracked in the corners below the cabinet. There were also other cracks in various places. I used WELD-ON for ABS to repair the cracks. It contains MEK which will melt and bond with the plastic. There are other threads on the forum about using MEK to repair the ABS plastic.
My results were mixed. The repair to the bottom corners of the cabinet did not hold. Once a little stress was re-introduced, the filler cracked. My long term solution to this is to use a piece of aluminum angle along the bottom edge and provide a support arm running down below the window. The aluminum hides the crack and the support should remove the stress to those joints.
For the other cracks, the WELD-ON worked well. I had to sand down the filler but once painted they are not really noticeable. Since there's no significant stress on these cracks (they all tended to originate from where rivets were used to secure the endcap), I expect them to hold.
If you go this route, you should drill a small hole at the end of the crack to keep it from cracking further and cut a V into the crack in which you apply the WELD-ON. Also, you should use protective gear. I actually purchased a full face mask/respirator off Amazon for the job. About $75 dollars and I love it. Works great, easy to get on/off, comfortable, and has been used a lot.