OT (sorta) What epoxy to fix a cracked Thule box?

[DRZRM]

So my wife must have backed up into an overhang...:rolleyes:

Seriously, came out the other morning and noticed a crack in the back of my Thule box. There was another thread about adhesives, and it seems that you guys have learned all there is to know about epoxies. What can I shmear on the inside to keep water from leaking in and to keep the crack from spreading? Matching grey a plus, but I figure I Can do most of the repair from the inside and it should not be too noticeable. It's on a 2005 Subaru anyway, so function over fashion.

[AngryScientist]

let's see a picture of the crack.

may have to drill a small hole on either side of the crack to prevent the stress from making the crack propagate.

[TimD]

Easier than you might think. Plenty of DIY out there. Good luck.

[dave thompson]

JB Weld is some wonderful stuff and perfect for gluing things together and filling cracks. When set, it's sandable and can be painted. Stop drill the ends of the cracks to prevent them from spreading, thoroughly clean both sides of the crack and use JB according to the directions. It will be fully set overnight and Bob's yer uncle.

[Louis]

If you're worried about the crack growing or the strength of the repair you could find some fiberglass cloth, make a patch, and using whatever adhesive you settle on, stick that on the inside of the box with an inch or two of cloth on either side of the crack.

[54ny77]

http://www.homedepot.com/p/Unbranded-FiberFix-2-in-x-1-4-yds-Repair-Wrap-857101004013/204413279

:hello:

[lemondvictoire]

I would use fiberglass cloth & resin to repair it and the repaired area would be stronger than new........First I would tape the outside cracked area to hold it together(tape to be removed after repair) and put patch on inside using couple layers of fiberglass cloth with resin.:)

[tombtfslpk]

West Systems
http://www.westsystem.com/ss/repair-kits/#plastic

[Tony]

So my wife must have backed up into an overhang...:rolleyes:

Seriously, came out the other morning and noticed a crack in the back of my Thule box. There was another thread about adhesives, and it seems that you guys have learned all there is to know about epoxies. What can I shmear on the inside to keep water from leaking in and to keep the crack from spreading? Matching grey a plus, but I figure I Can do most of the repair from the inside and it should not be too noticeable. It's on a 2005 Subaru anyway, so function over fashion.

I used this product called Flex Set to make a skeg for my kayak, bonding plastic to steel Its a very tenacious epoxy that holds tight to plastics, stainless steel and composites.
https://plus.google.com/photos/107709068384636814318/albums/5898995027277950657

Here I used it to armor my composite boat with stainless steel.
https://plus.google.com/photos/107709068384636814318/albums/5883834219615316609

Flex set works best when you heat the plastic, shinny in appearance, than apply it to the repair area.

Using G flex and fiberglass tape to reinforce the inside may work ok. Not sure what type of plastic the Thule box is made from. Your best option may be to plastic weld the inside using a pencil touch with fine tip kneading the plastic together

[raygunner]

Great thread!

I have a cracked Tri-All-3 case that needs some fixin'.

[ultraman6970]

Hm... cracked saddle.... fiberfix hmm....

[mjb266]

The epoxy fix is elegant. I used two sheets of aluminum and sandwiched the box between them after bending to fit the contours. Drilled and screwed together with stainless hardware. 30-45 minutes and plenty strong.

[DRZRM]

Thanks for all the helpful replies, I knew this was the place to ask. MJB, did you leave the aluminum plate on, or pull it once the epoxy set?

Edit: Oh, I get it, you didn't glue, just used aluminum plates. Slow on the uptake.

The epoxy fix is elegant. I used ttwo sheets of aluminum and sandwiched the box between them after bending to fit the contours. Drilled and screwed together with stainless hardware. 30-45 minutes and plenty strong.

[nahtnoj]

I fixed mine with fiberglass. JB would work too. I also used some aluminum straps on the inside to reinforce since it was a pretty long crack.