Snow
Super Active Member
- Jul 19, 2007
- 12,323
I see a new winter hobby for you, repairing pup storage boxes ... ![[:D]](/smileys/smile_big.gif "Big Smile [:D]")
![[;)]](/smileys/smile_wink.gif "Wink [;)]")
Front Storage Box Repair
- Thread starter jman1200
- Start date
REPAIRING THE ABS PANELS
This post is about how I repaired the cracks and a hole I had on the ABS panels. There were a total of 9 cracks (two of them I caused when disassembling![[:(]](/smileys/smile_sad.gif "Sad [:(]")
by trying to detach the butyl tape by pulling on a panel) and one hole which as per the PO, was caused by a stone being trapped behind the lid when he opened it.
I recommend this to be one of the very last steps of your rebuild, the repaired areas might break again with all the handling that's involved to fit these panels.
The first thing I did was remove all the old butyl tape, silicone and some old epoxy that the PO used to "repair" (yeah, right !) the hole. Then I removed all the leftover glue and cleaned very well the areas were I was going to apply the epoxy.
After cleaning, I sanded the areas to rough up the surface and on top of that, using an exacto knife, I created some surface scratches for the epoxy to adhere much better.
[url=https://flic.kr/p/21hxoPh]
20141113-01490-2 by JP M, on Flickr[/URL]
I taped the panels on the outside to keep everything tight and together during the process
[url=https://flic.kr/p/DcChZA]
20141113-01492-2 by JP M, on Flickr[/URL]
I used Marine-Tex which is a product I highly recommend. It is expensive but you don't need too much. I bought this kit two years ago to fix a Waverunner and had more than half of it left. Depending on what you are fixing you might be able to get it done with a smaller kit but I do have to say that as stated on the instructions, thicker coats dry faster.
[url=https://flic.kr/p/21hxsDb]
20141113-01493-2 by JP M, on Flickr[/URL]
I took the panels inside (again DW was not happy about it), Marine-Tex needs more than 22C (72F) to dry. I left them with an oscillating heat lamp overnight.
[url=https://flic.kr/p/DcCjis]
20141113-01495-2 by JP M, on Flickr[/URL]
I'm not planning on sanding any of these as they all are on the inside. I also didn't want to apply any Marine-Tex on the outside because I rather see a thin line than a patch with a different tone of white.
This post is about how I repaired the cracks and a hole I had on the ABS panels. There were a total of 9 cracks (two of them I caused when disassembling
by trying to detach the butyl tape by pulling on a panel) and one hole which as per the PO, was caused by a stone being trapped behind the lid when he opened it.I recommend this to be one of the very last steps of your rebuild, the repaired areas might break again with all the handling that's involved to fit these panels.
The first thing I did was remove all the old butyl tape, silicone and some old epoxy that the PO used to "repair" (yeah, right !) the hole. Then I removed all the leftover glue and cleaned very well the areas were I was going to apply the epoxy.
After cleaning, I sanded the areas to rough up the surface and on top of that, using an exacto knife, I created some surface scratches for the epoxy to adhere much better.
[url=https://flic.kr/p/21hxoPh]
20141113-01490-2 by JP M, on Flickr[/URL]I taped the panels on the outside to keep everything tight and together during the process
[url=https://flic.kr/p/DcChZA]
20141113-01492-2 by JP M, on Flickr[/URL]I used Marine-Tex which is a product I highly recommend. It is expensive but you don't need too much. I bought this kit two years ago to fix a Waverunner and had more than half of it left. Depending on what you are fixing you might be able to get it done with a smaller kit but I do have to say that as stated on the instructions, thicker coats dry faster.
[url=https://flic.kr/p/21hxsDb]
20141113-01493-2 by JP M, on Flickr[/URL]I took the panels inside (again DW was not happy about it
), Marine-Tex needs more than 22C (72F) to dry. I left them with an oscillating heat lamp overnight.[url=https://flic.kr/p/DcCjis]
20141113-01495-2 by JP M, on Flickr[/URL]I'm not planning on sanding any of these as they all are on the inside. I also didn't want to apply any Marine-Tex on the outside because I rather see a thin line than a patch with a different tone of white.
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WOOD PANELS
This is what I'll call a Bonus Section
The following pics show the measurements in centimeters (divide by 2.54 to convert to inches) of each one of the wood pieces required to build this box. They apply to the 2000 Bayside model, not sure if they are the same on any other models/year.
There are 3 layouts, one for 5/8", 1/2" and 5mm wood panels with the pictures showing the corresponding piece and their location. Hope this helps someone down the road.
[url=https://flic.kr/p/21hvqj5]
Wood 5-8 by JP M, on Flickr[/URL]
[url=https://flic.kr/p/21hvq9W]
Wood 1-2 by JP M, on Flickr[/URL]
[url=https://flic.kr/p/GoL3dr]
Wood 5 mm by JP M, on Flickr[/URL]
[url=https://flic.kr/p/DcAZDA]
Wood Panels 1 by JP M, on Flickr[/URL]
[url=https://flic.kr/p/21hvtdm]
Wood Panels 2 by JP M, on Flickr[/URL]
[url=https://flic.kr/p/DcB2x5]
Wood Panels 3 by JP M, on Flickr[/URL]
Use this guide at your own risk and remember, measure twice cut once ! My lawyer told me to tell you this
This is what I'll call a Bonus Section
The following pics show the measurements in centimeters (divide by 2.54 to convert to inches) of each one of the wood pieces required to build this box. They apply to the 2000 Bayside model, not sure if they are the same on any other models/year.
There are 3 layouts, one for 5/8", 1/2" and 5mm wood panels with the pictures showing the corresponding piece and their location. Hope this helps someone down the road.
[url=https://flic.kr/p/21hvqj5]
Wood 5-8 by JP M, on Flickr[/URL][url=https://flic.kr/p/21hvq9W]
Wood 1-2 by JP M, on Flickr[/URL][url=https://flic.kr/p/GoL3dr]
Wood 5 mm by JP M, on Flickr[/URL][url=https://flic.kr/p/DcAZDA]
Wood Panels 1 by JP M, on Flickr[/URL][url=https://flic.kr/p/21hvtdm]
Wood Panels 2 by JP M, on Flickr[/URL][url=https://flic.kr/p/DcB2x5]
Wood Panels 3 by JP M, on Flickr[/URL]Use this guide at your own risk and remember, measure twice cut once ! My lawyer told me to tell you this
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Ok, now let's get back to the progress updates:
The following might be a bit overkill but I had a bunch of rubberized paint cans that a friend gave me so I decided to use them and also clean up some shelf space in my cabinets. Some other people have used exterior use paint and some others just left the wood exposed so it can breathe. I painted the box once it was fully assembled to seal any cracks or gaps on the top and side panels.
[url=https://flic.kr/p/DcChbm]
20141113-01485-2 by JP M, on Flickr[/URL]
[url=https://flic.kr/p/21kmmLn]
20141113-01503-2 by JP M, on Flickr[/URL]
The following might be a bit overkill but I had a bunch of rubberized paint cans that a friend gave me so I decided to use them and also clean up some shelf space in my cabinets. Some other people have used exterior use paint and some others just left the wood exposed so it can breathe. I painted the box once it was fully assembled to seal any cracks or gaps on the top and side panels.
[url=https://flic.kr/p/DcChbm]
20141113-01485-2 by JP M, on Flickr[/URL][url=https://flic.kr/p/21kmmLn]
20141113-01503-2 by JP M, on Flickr[/URL]
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The saga continues...
Applied the flashing tape to all top ends, forgot to take a pic but this one shows how the box looked like before re-attaching the ABS.
[url=https://flic.kr/p/21kmq56]
20141115-01515-2 by JP M, on Flickr[/URL]
Painted the gas line plastic cover. I believe great things are made by the sum of small details !
[url=https://flic.kr/p/21kmook]
20141115-01512-2 by JP M, on Flickr[/URL]
[url=https://flic.kr/p/ZfxNLY]
20141115-01516-2 by JP M, on Flickr[/URL]
Replaced the old supports with aluminum ones to better match the new decoration
[url=https://flic.kr/p/21kDuic]
20141115-01513-2 by JP M, on Flickr[/URL]
Although I coudn't find any hairline cracks here, I added a coat of Leak Seal to the interior of the top ABS panel. I masked the areas where the butyl tape goes.
Note the areas where the Marine-Tex was applied.
[url=https://flic.kr/p/21fvC93]
20141115-01519-2 by JP M, on Flickr[/URL]
[url=https://flic.kr/p/ZfxQM1]
20141115-01521-2 by JP M, on Flickr[/URL]
Applied the flashing tape to all top ends, forgot to take a pic but this one shows how the box looked like before re-attaching the ABS.
[url=https://flic.kr/p/21kmq56]
20141115-01515-2 by JP M, on Flickr[/URL]Painted the gas line plastic cover. I believe great things are made by the sum of small details !
[url=https://flic.kr/p/21kmook]
20141115-01512-2 by JP M, on Flickr[/URL][url=https://flic.kr/p/ZfxNLY]
20141115-01516-2 by JP M, on Flickr[/URL]Replaced the old supports with aluminum ones to better match the new decoration
[url=https://flic.kr/p/21kDuic]
20141115-01513-2 by JP M, on Flickr[/URL]Although I coudn't find any hairline cracks here, I added a coat of Leak Seal to the interior of the top ABS panel. I masked the areas where the butyl tape goes.
Note the areas where the Marine-Tex was applied.
[url=https://flic.kr/p/21fvC93]
20141115-01519-2 by JP M, on Flickr[/URL][url=https://flic.kr/p/ZfxQM1]
20141115-01521-2 by JP M, on Flickr[/URL]
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A decided to tape the side panels to the front one and then position them as a whole. I thought that the butyl tape could get wrinkled if I tried to later slide the side panel under the front one. DW had to help maneuver .
20141115-01517-2 by JP M, on Flickr
20141115-01518-2 by JP M, on Flickr
20141115-01523-2 by JP M, on Flickr
The arrow on the previous pic shows the top aluminum trim. I applied a bead of silicone to seal it so as to the area around it.
20141118-01544-2 by JP M, on Flickr
I wrapped some butyl around the bolts that secure the lid to seal them better. I applied the butyl tape to the hinge and then positioned all the bolts before attempting to position the lid in place. Again, DW came to help guide the lid in place.
20141116-01529-2 by JP M, on Flickr
20141116-01530-2 by JP M, on Flickr
Drilled new holes for the front lid locks. Applied more butyl tape under them.
20141116-01532-2 by JP M, on Flickr
20141116-01533-2 by JP M, on Flickr
Installed the interior lamp. The metal plate in the pic needs to be adjusted so it makes contact with the back of the lamp to prevent it from flexing down when the lid closes.
20141116-01537-2 by JP M, on Flickr
I went to grab the LED strip I had for the storage box but it broke when I tried to straighten it![[:!]](/smileys/smile_worried.gif "Worried [:!]")
. It had been sitting in my car that was parked outside in the cold.
I did run the wires I'll need to install a new strip later.
.
20141115-01517-2 by JP M, on Flickr
20141115-01518-2 by JP M, on Flickr
20141115-01523-2 by JP M, on FlickrThe arrow on the previous pic shows the top aluminum trim. I applied a bead of silicone to seal it so as to the area around it.
20141118-01544-2 by JP M, on FlickrI wrapped some butyl around the bolts that secure the lid to seal them better. I applied the butyl tape to the hinge and then positioned all the bolts before attempting to position the lid in place. Again, DW came to help guide the lid in place.
20141116-01529-2 by JP M, on Flickr
20141116-01530-2 by JP M, on FlickrDrilled new holes for the front lid locks. Applied more butyl tape under them.
20141116-01532-2 by JP M, on Flickr
20141116-01533-2 by JP M, on FlickrInstalled the interior lamp. The metal plate in the pic needs to be adjusted so it makes contact with the back of the lamp to prevent it from flexing down when the lid closes.
20141116-01537-2 by JP M, on FlickrI went to grab the LED strip I had for the storage box but it broke when I tried to straighten it
. It had been sitting in my car that was parked outside in the cold.I did run the wires I'll need to install a new strip later.
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Snow
Super Active Member
- Jul 19, 2007
- 12,323
Nice Uhaul blanket .. .. we have one in the TT as well ... ![[LOL]](/smileys/smile_lol.gif "Laugh Out Loud [LOL]")
.. we have one in the TT as well ... Found the pic showing where the flashing tape was applied... I new I had it somewhere ![[CAM]](/smileys/smile_camera.gif "Camera [CAM]")
[url=https://flic.kr/p/DcCmK1]
20141115-01506-2 by JP M, on Flickr[/URL]
[url=https://flic.kr/p/DcCmK1]
20141115-01506-2 by JP M, on Flickr[/URL]
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Last night I finished pimping my water heater. It was rusty so I decided to give it a face lift with some heat resistant paint. I added some color to it which you will only be able to see when you open the access door.
This is how it looked when I removed it
[url=https://flic.kr/p/21hvkYS]
Heater by JP M, on Flickr[/URL]
In process...
[url=https://flic.kr/p/21hvd2E]
20141117-01543-2 by JP M, on Flickr[/URL]
[url=https://flic.kr/p/21fvEd3]
20141116-01527-2 by JP M, on Flickr[/URL]
[url=https://flic.kr/p/DcCumU]
20141117-01542-2 by JP M, on Flickr[/URL]
Done
[url=https://flic.kr/p/21hvhnd]
20141119-01547-2 by JP M, on Flickr[/URL]
Installed
[url=https://flic.kr/p/21hvjqG]
20141119-01554-2 by JP M, on Flickr[/URL]
This is how it looked when I removed it
[url=https://flic.kr/p/21hvkYS]
Heater by JP M, on Flickr[/URL]In process...
[url=https://flic.kr/p/21hvd2E]
20141117-01543-2 by JP M, on Flickr[/URL][url=https://flic.kr/p/21fvEd3]
20141116-01527-2 by JP M, on Flickr[/URL][url=https://flic.kr/p/DcCumU]
20141117-01542-2 by JP M, on Flickr[/URL]Done
[url=https://flic.kr/p/21hvhnd]
20141119-01547-2 by JP M, on Flickr[/URL]Installed
[url=https://flic.kr/p/21hvjqG]
20141119-01554-2 by JP M, on Flickr[/URL]
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I'm glad to announce that this project is finally done... it took me around 80 hours in 36 days to complete it but I think it was totally worth it. I learned a lot of things in the process and kept me entertained for a while. Thanks to all who helped, cheered and gave your advise.
I sealed the area where the ABS panels meet the aluminum side panels, mi trailer has a large gap on the top of both sides.
[url=https://flic.kr/p/GoL2Pv]
20141120-01568-2 by JP M, on Flickr[/URL]
The left side showing the facelifted water heater
[url=https://flic.kr/p/21hvjTq]
20141120-01561-2 by JP M, on Flickr[/URL]
The right side... on the top right end you can see the wires I ran to install the LED strip in the near future
[url=https://flic.kr/p/GoKZkx]
20141120-01563-2 by JP M, on Flickr[/URL]
Full view. I re-used the middle wood panel as it was in good shape, but still added a plastic strip under it to keep it away from any water.
[url=https://flic.kr/p/21hvnV7]
20141120-01565-2 by JP M, on Flickr[/URL]
[url=https://flic.kr/p/GoL1RD]
20141120-01567-2 by JP M, on Flickr[/URL]
!
I sealed the area where the ABS panels meet the aluminum side panels, mi trailer has a large gap on the top of both sides.
[url=https://flic.kr/p/GoL2Pv]
20141120-01568-2 by JP M, on Flickr[/URL]The left side showing the facelifted water heater
[url=https://flic.kr/p/21hvjTq]
20141120-01561-2 by JP M, on Flickr[/URL]The right side... on the top right end you can see the wires I ran to install the LED strip in the near future
[url=https://flic.kr/p/GoKZkx]
20141120-01563-2 by JP M, on Flickr[/URL]Full view. I re-used the middle wood panel as it was in good shape, but still added a plastic strip under it to keep it away from any water.
[url=https://flic.kr/p/21hvnV7]
20141120-01565-2 by JP M, on Flickr[/URL][url=https://flic.kr/p/GoL1RD]
20141120-01567-2 by JP M, on Flickr[/URL] !
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Snow
Super Active Member
- Jul 19, 2007
- 12,323
Looks great ... Hope to see it in person at the 2015 Ontario Rally ...
jnc
Welcome from New Hampshire
It looks great! Can I ship you mine ? Wishful thinking I know. I don't believe that I can do as good a job as you have. I am not that patient. Thanks for the show I enjoyed watching your build.
jnc said:
Thanks for the compliments !
When I decided to fix my storage box, I thought I'd just be replacing a 1 or 2 feet section on the right end of the floor, "just a patch" I said to myself and you already know what I ended up doing.
Although I am mechanically inclined, I have very little experience when it comes to wood work, I don't think it was that hard, very basic stuff. If you don't have the patience, just plan to spend more time fixing it, make it an event, bbqs, some beers, music while you are at it.
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