I didn't want to add to this thread until I had finished, but I've run into an issue and could use some advice.
So I used some donor ABS plastic I got from an old speaker grille in the car. I melted it onto the console in the areas where it had cracked.
Thanks Mr Oval Whizzer - whatever that means
Next I sanded it down flat
Obviously this has removed the plastic texture, but that's ok as I'm going to spray Duplicolor bed liner spray when I'm done to try and simulate that textured style.
I noticed that there was still some gaps from my plastic welding and I decided to experiment with those hairline cracks and try to fill them with this epoxy.
It did manage to fill the gaps, but it's not a coloured glue so it sets dry and you can still see the hairline cracks under it. I have since bought some similar stuff from Supercheap Auto called Permatex Permapoxy 5 Minute Plastic Weld - 25mL.
http://www.supercheapauto.com.au/online-store/products/Permatex-Permapoxy-5-Minute-Plastic-Weld-25mL.aspx?pid=129945#Cross
Which i'll give a try and let you know how it pans out...
This brings me to the next step.. fixing a large gap / crack..I bought a fiberglass repair kit to try and fix these issues..
1. If you look back at a previous photo you'll see where the gearbox gaiter/boot clips onto the console there is some damage to the plastic. A large crack and a missing bit of the plastic.
So I sanded the affected area and lay down the fiberglass matting and resin with a brush to try and re-enforce the area.
I also lay some fiberglass on the underside of the console where the cracks were before plastic welding them.
Finally I also decided to apply a small patch around 1 of the screw holes that got a bit reamed out when removing it from the car - due to a rusted screw.
These photos were taken last night, I checked this morning and it appears that the resin is still sticky / wet and hasn't set?
Photos from this morning..
Under cracks was a bit better
Other photos
I thought that perhaps the catalyst / resin mixture wasn't done right (50ml to 20 drops of catalyst was the mixture), but looking in the mixing cup this morning I noticed it had no trouble setting rock hard!
Hmm yummy!
Questions:
1. So why wouldn't the fiberglass set when left overnight? I left the console on a table outside under cover, but the grass has condensation on it in the morning, is it the moisture in the air preventing it from setting?
When I left the house I left it sitting in the sun on the table, just in case.
2. Shamefully I didn't use wax and grease remover before laying down the fiberglass - I realised my mistake after I started - is this causing the problem?
Also I only sanded the surface where the massive crack was under the gear stick boot, I didn't sand the area under the crack or around the screw hole (brain fart ).
3. What causes the resin to not set hard to the mixing cup? Will it not bond to certain plastics? Is my console made from the same kind of plastic do you think? Hence why it won't set on this surface?
4. Have I done anything else wrong?