How to get a fresh front storage box

dmc94572 · 03-25-2022, 08:05 PM

Cracked a nice hole passenger side outter edge. Costlier to fix than a replacement. ETI won't ship one. Gotta get it there. 2000 miles round trip $1000 in just gas to get it. Not heading north. Plans are to go South from SF Bay Area. Anyone heading to ETI from SF this year? I'd make it worth your while to get it for me. You can see the damage in this photo. Thanks, David

**Donna D.** · 03-25-2022, 08:19 PM

Well, this would be a perfect project to start your fiberglass RV repair knowledge. What have you got to lose? There's plenty of info here at the EscapeForum and at West Marine and other places.

We'll all cheer you on and if you really document the process, you'll be helping someone in the future.

Best of luck

dmc94572 · 03-25-2022, 08:23 PM

Yes you are right Donna. I bought that nasty special order paint already. No rush thats for sure.

sofmerc · 03-25-2022, 08:46 PM

Quote:

Originally Posted by dmc94572

Cracked a nice hole passenger side outter edge. Costlier to fix than a replacement. ETI won't ship one. Gotta get it there. 2000 miles round trip $1000 in just gas to get it. Not heading north. Plans are to go South from SF Bay Area. Anyone heading to ETI from SF this year? I'd make it worth your while to get it for me. You can see the damage in this photo. Thanks, David

You can fix this for about $40 in materials and about 4 hrs labor... Youtube videos are your friend

HABBERDABBER · 03-25-2022, 09:34 PM

Bummer.
You or someone can patch that box to look good for a lot less than new, if you could even get a new one.

How about a temporary patch of white duct tape? Don't laugh. That would keep things weathertight until your repairs are completed. I'd patch that with some building supply available, adhesive roof film patch that comes in larger sheets and is white. Poke the fiberglass out as good as you can and patch over it. A patch on each side of the box for symmetry. Temporary, of course.

Boat repair places deal with this sort of damage every day.

Centex · 03-26-2022, 12:02 AM

Quote:

Originally Posted by HABBERDABBER

.... How about a temporary patch of white duct tape? Don't laugh. That would keep things weathertight until your repairs are completed. ...

Gaffer's tape rather than duct tape is my suggestion for this application. Essentially the same properties but less / easier adhesive residue removal.

Just for your consideration, Have Fun!

dmc94572 · 03-26-2022, 08:27 PM

Thanks for a vote of confidence! Boat repair places labor rates are probably around $200 per hour. But $800 is not of interest to them. My concern like all repairs that are foreign, what tools must I collect? What are the prospects for success. Will that foot some kind soul added to the damage make this a bridge too far? The YouTube videos seem to cover easier applications. I will update a fresh photo of the damage.

Ron in BC · 03-26-2022, 09:47 PM

That's a perfect case to learn on. Really forgiving, mostly because there's no large chunk of f.g. missing, no big hole to fill and make match to the contour.

Briefly, the process is: rough sand the interior around the damage. Then push out the pushed in piece, use a stick to hold it pushed in position flush as best you can.

Then you take some mat and resin and put in on the interior. After it sets up you can add one or two more layers. That restores the structure and holds things in place.

Then you lightly grind or sand the exterior a couple of inches around the damaged area. You could use resin to fill the surface cracks etc but gelcoat is easier to sand. Since the surface coating is textured it's a very forgiving situation.

The first step is quick and simple, makes the area water tight and strong and you can do the second step separately when you have time.

Ron

HABBERDABBER · 03-26-2022, 10:01 PM

Quote:

Originally Posted by dmc94572

Thanks for a vote of confidence! Boat repair places labor rates are probably around $200 per hour. But $800 is not of interest to them. My concern like all repairs that are foreign, what tools must I collect? What are the prospects for success. Will that foot some kind soul added to the damage make this a bridge too far? The YouTube videos seem to cover easier applications. I will update a fresh photo of the damage.

Typically, the tools needed are minimal, if it is fracture of the shell with no missing pieces. Various grits of sandpaper, some plastic putty knives, fiberglass cloth, protective gloves, packing tape, disposable brushes, other sundry items. Maybe some Bondo too.

Others will chime in, but I've been using W.E.S.T. epoxy resins for years and have had much better results with that than using polyester resin (your box is made with that). Your issue is cosmetic and not structural, so quibbles of adhesion, etc. don't seem to be a primary concern. The epoxy will adhere, well. Very well.

Much depends on the extent of your damage. Several photos are crucial to understanding your project.

This ain't rocket science. If you can read instructions, you can repair it. How well you repair it and how invisible the repair becomes depends on your patience, attention to detail and time spent. Making something useable and presentable again takes lot less time than making it original looking. Nobody is going to care or see the inside, and that's where much of your repair work will be done.
Enough of my lecturing. In my defense, I was a teacher, briefly.

lonewolfjb · 03-26-2022, 10:39 PM

Quote:

Originally Posted by dmc94572

Cracked a nice hole passenger side outter edge. Costlier to fix than a replacement. ETI won't ship one. Gotta get it there. 2000 miles round trip $1000 in just gas to get it. Not heading north. Plans are to go South from SF Bay Area. Anyone heading to ETI from SF this year? I'd make it worth your while to get it for me. You can see the damage in this photo. Thanks, David

David, have you checked any surfboard shops up your way I'm sure they could recommend a board repair shop that could repair that very easy?

Steven M · 03-27-2022, 10:16 AM

My local, at the time, hot rod shop/ Corvette repair fixed a similar crack in my storage box for $350 including a complete respray with bedliner. Time was the biggest factor in the repair. Check around for a local shop that specializes in Vettes or general fiberglass repair. That includes boats, though I haven't found one around here who would. I think they were spooked by some previous job that wasn't to the customers satisfaction.

Bobbie54 · 03-27-2022, 10:34 AM

Not a lot of tools. Fiberglass cloth, resin, and a paintbrush. A place to work outside. Paint to match. (Or repair from the inside and leave barely visible cracks and no need to paint.)

Ron in BC · 03-27-2022, 10:46 AM

Quote:

Originally Posted by HABBERDABBER

Others will chime in, but I've been using W.E.S.T. epoxy resins for years and have had much better results with that than using polyester resin (your box is made with that). Your issue is cosmetic and not structural, so quibbles of adhesion, etc. don't seem to be a primary concern. The epoxy will adhere, well. Very well.

Yup, I chime in every time I see someone mention using epoxy.

There's no need for it and you burn a bridge when you use it. Epoxy does indeed adhere well. But polyester resin doesn't adhere to epoxy. So by using epoxy you can't use polyester gelcoat or resin over it if the area needs a future repair. Epoxy sticks to polyester, polyester doesn't adhere very well to epoxy.

No need to use epoxy, do the whole repair using polyester. My advice is to do the interior and see what the exterior looks like after that.

Ron

oldwave · 03-27-2022, 11:19 AM

Quote:

Originally Posted by Centex

Gaffer's tape rather than duct tape is my suggestion for this application. Essentially the same properties but less / easier adhesive residue removal.

Just for your consideration, Have Fun!

Gaffers is not waterproof however

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