After a tumble or moment of mechanical ineptitute we frequently find ourselves with cracked or broken plactics. Various blue peter methods are out there to rectify these as well as some pricey commercial altenatives. I have a brake light with a broken lug and as they are probably the most awkward I thought I'd share the process with you.
The damage - as you can see the middle lug is missing. While not essential as the light will still attach it is a good example.
How it should be - this is the back of a shattered light which someone kindly took a brick to so a straight swap is out of the question.
The cure - these kits are available from ebay and come is various sizes. last year I purchased a simple one colour kit. I have since obtained a second kit which does white, black and clear colours. It comes with a nice dvd of instructions.
The kit for todays lesson - basically its a form of chemical welding the solvent on its own can be used to repair cracks. Added to the plastic powder it becomes a form of plastic polyfiller which attaches itself to the old part.
The white blob at the bottom is the moulding bar which has the impression of the lug I had to make last year when my bike was dropped after an attempted theft.
To rebuild the lug we need a mould of a good one - Clean the area to mould from and pop the bar or blob into a cup of boiled water
After about 5 mins when its nice and squidqy take it out, squash around the area and through any holes. The cold blob is still pliable and can simply be pulled off when its cold.
When its cold take it off and put on the one to be repaired.
Basically the next step is to drip plastic and solvent into the void - first you drip solvent only into the void to soften the broken edges - next you drip solvent into the tub of plastic powder to make a ball of molten plastic which you deposit into the hole with more solvent.
After a few minutes of gentle work you should have rebuilt the lug filling the void with compound
Leave to cure for a few minutes then the moulding blob can be removed leaving the rough casting. More plastic can be added to fill any large holes. The finished result will probably need a gentle file to finalise the shape.
These kits can be used to fill holes and cracks as well, the larger kits are multi colour with fibreglass reinforcement. The only drawback will be the solvent disappearing into the atmospere. fortunately extra bottles can be obtained from the supplier.
The only thing you cant fix with these are the black interior panels as they are a different plastic according to lawrie.
Have fun :-)
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