On Sat, 22 Jul 2006 09:57:25 +0100, "Andy Luckman (AJL Electronics)"
wrote:
First, DO NOT BUY the glassfibre kits in the high street. They are over fast
in their going off. Your resin will last two or three minutes in this heat,
about ten in normal temperatures. Purchase some proper resin, matting and
catalyst from a professional company. You will have up to an hour working
time.
Cut lots of aluminium fingers and drill a 4mm hole in each end of the
finger. Get some cellophane and cut long strips that will cover the slot
between parts and some to the sides. If the joint butts accurately, you can
dispense with the cellophane.
Screw the fingers using short self tappers over the cellophane such to cover
the slot and hold the pieces in correct alignment.
Using an angle grinder with a STONE disc, grind out the other side so that
the joint tapers over some reasonable area.
Make up a small amount of resin and paint over the joint. Leave to set and
then do the same again, having made up some extra resin.
Lay a piece of matting onto the wet resin and stipple the resin in as if you
were painting through a template. Short bristles help. Do not use a
"painting" motion. If you are brave, you could lay more pieces of matting,
but make them different sizes. Do not lay too much in one go.
Make sure that all the matting is fully impregnated and rolled out to remove
air bubbles.
Repeat as required until the joint is about level and strong.
Now you can remove the screws and fingers, leaving just the holes to fill.
Finish as required with polyester filler and paint to match.
To do the repair properly requires more or less what you said above
but it needs doing from BOTH sides.
Grinding halfway through and taper repairing one side then letting it
go off, then removing the strips of aluminium used for joint alignment
followed by grinding out the other side and using resin and matting in
a similar manner makes for a much stronger joint.
www.cfsnet.co.uk or
http://www.glasplies.co.uk/ will have all the
original poster needs.
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