Hello,

When I got my 1996 Corvette the battery cover panel was broken. The panel looked perfect but some of the mounts were broken. I looked around for a new one but I wasn't having much luck. I decided to use a little experience from my other hobby, model planes and helicopters. I had some of the broken plastic parts. I used CA super glue and put the parts I had back in place. Then I used some paper to make a pattern of the rest of the parts I needed to make to make mounting surface whole again. Using 3/32" hard plywood I made parts from the patterns. I glued those wood pieces in place and the mounts are now whole. But they wont hold. They would just break again.

I pulled out the ProSet Epoxy, the good stuff, and some 90 lbs carbon fiber. The ProSet epoxy is strong stuff. It can I used to make airplane parts. Mine is very old so the hardener has turned brown. It still works but the pot life and the cure times are different than advertised. Once it turns brown it's not rated like it was and should not be used for structural parts. But for items like this it will be good. I sanded the surfaces smooth so all the seams would be even. Then using the epoxy I applied a layer of carbon on both sides of the part. After it hardens, 24 hours, I will apply a second layer of carbon fiber.

I have attached some pics of the process.


Borken pieces glued back in place.

Broen pieces glued back in place.

Broken lower mount.

Making Pattern out of paper where there is no part.

What the pattern looks like.

New wood pieces that will fill the missing areas.

Wood piece in place.

Back side sanded smooth.

Front side sanded smooth.

Applied some tape to keep any extra glue from getting on the face of the panel. 90 Lbs carbon and the pizza cutter Xacto knife.

ProSet epoxy.

Epoxy ready to go. This stuff is tough and should be used with care in a ventilated area with gloves and protective glasses.

Carbon applied to the front.

Carbon applied to the inside of the mount.

Carbon applied to both sides of the lower mount.

Inside the lower mount.

 

That looks like it will be a good fix and will be much more substantial than original.
Be sure to post final pics of the project.

 

Looks great hopefully it will bond to the SMC. If not try a product like 3M 8115 or one of the other SMC compliant bonding agents.

 

SMC that is material the panel is made from? The CA glue attached to it instantly! So the epoxy should attach to it as well. I will test it with some good hard pulls on it.

Some plastics and woods are weird. Stuff from china, nothing sticks to some of that stuff and CA will stick it almost anything it touches, especially your skin.

 

Its more of a plastic but the SMC products will repair it. Great repair all that counts is that it holds up.

 

The part is done. Turned out great. It’s super strong. It won’t need a second coat of carbon fiber.