Front Storage Box Repair

Discussion in 'Roof/Floor Repair & Maintenance' started by jman1200, Oct 15, 2014.

  1. Snow

    Snow Well-Known Member

    8,805
    351
    Jul 19, 2007
    Ontario
    I see a new winter hobby for you, repairing pup storage boxes ... [:D] [;)]
     
  2. jman1200

    jman1200 http://i529.photobucket.com/albums/dd340/jmanotas/

    1,265
    5
    Nov 11, 2013
    Ontario
    Yes, I'm sure the next one won't take me as long.... now, who's willing to pay my rates ! [:D] [LOL]
     
  3. ewils35

    ewils35 Member

    66
    0
    Oct 14, 2014
    Body repair rates go for 42 bucks an hour here in Detroit lol
     
  4. jman1200

    jman1200 http://i529.photobucket.com/albums/dd340/jmanotas/

    1,265
    5
    Nov 11, 2013
    Ontario
    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 [:(] 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.

    [​IMG]20141113-01490-2 by JP M, on Flickr

    I taped the panels on the outside to keep everything tight and together during the process

    [​IMG]20141113-01492-2 by JP M, on Flickr

    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.

    [​IMG]20141113-01493-2 by JP M, on Flickr

    I took the panels inside (again DW was not happy about it [:D]), Marine-Tex needs more than 22C (72F) to dry. I left them with an oscillating heat lamp overnight.

    [​IMG]20141113-01495-2 by JP M, on Flickr

    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.
     
    Last edited: Nov 9, 2017
  5. jman1200

    jman1200 http://i529.photobucket.com/albums/dd340/jmanotas/

    1,265
    5
    Nov 11, 2013
    Ontario
    WOOD PANELS

    This is what I'll call a Bonus Section [:D]

    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.

    [​IMG]Wood 5-8 by JP M, on Flickr

    [​IMG]Wood 1-2 by JP M, on Flickr

    [​IMG]Wood 5 mm by JP M, on Flickr

    [​IMG]Wood Panels 1 by JP M, on Flickr

    [​IMG]Wood Panels 2 by JP M, on Flickr

    [​IMG]Wood Panels 3 by JP M, on Flickr

    Use this guide at your own risk and remember, measure twice cut once ! My lawyer told me to tell you this [:D]
     
    Last edited: Nov 9, 2017
  6. jman1200

    jman1200 http://i529.photobucket.com/albums/dd340/jmanotas/

    1,265
    5
    Nov 11, 2013
    Ontario
    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.

    [​IMG]20141113-01485-2 by JP M, on Flickr

    [​IMG]20141113-01503-2 by JP M, on Flickr
     
    Last edited: Nov 9, 2017
  7. ewils35

    ewils35 Member

    66
    0
    Oct 14, 2014
    Looks good jman my project is on hold as I possibly fractured my ankle yesterday. Keep up the good work!
     
  8. jman1200

    jman1200 http://i529.photobucket.com/albums/dd340/jmanotas/

    1,265
    5
    Nov 11, 2013
    Ontario
    Sorry to hear that, hopefully it's not fractured.
     
  9. ewils35

    ewils35 Member

    66
    0
    Oct 14, 2014
    Woke up this morning and started walking on it and it loosened up to where I'm not hobbling around anymore so its telling me its only a sprain
     
  10. jman1200

    jman1200 http://i529.photobucket.com/albums/dd340/jmanotas/

    1,265
    5
    Nov 11, 2013
    Ontario
    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.

    [​IMG]20141115-01515-2 by JP M, on Flickr

    Painted the gas line plastic cover. I believe great things are made by the sum of small details !

    [​IMG]20141115-01512-2 by JP M, on Flickr

    [​IMG]20141115-01516-2 by JP M, on Flickr

    Replaced the old supports with aluminum ones to better match the new decoration [:D]

    [​IMG]20141115-01513-2 by JP M, on Flickr

    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.

    [​IMG]20141115-01519-2 by JP M, on Flickr

    [​IMG]20141115-01521-2 by JP M, on Flickr
     
    Last edited: Nov 9, 2017
  11. jman1200

    jman1200 http://i529.photobucket.com/albums/dd340/jmanotas/

    1,265
    5
    Nov 11, 2013
    Ontario
    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 [:D].

    [​IMG]20141115-01517-2 by JP M, on Flickr

    [​IMG]20141115-01518-2 by JP M, on Flickr

    [​IMG]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.

    [​IMG]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.

    [​IMG]20141116-01529-2 by JP M, on Flickr

    [​IMG]20141116-01530-2 by JP M, on Flickr

    Drilled new holes for the front lid locks. Applied more butyl tape under them.

    [​IMG]20141116-01532-2 by JP M, on Flickr

    [​IMG]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.

    [​IMG]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 [:!]. 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.
     
    Last edited: Nov 9, 2017
  12. Snow

    Snow Well-Known Member

    8,805
    351
    Jul 19, 2007
    Ontario
    Nice Uhaul blanket .. [;)] .. we have one in the TT as well ... [LOL]
     
  13. jman1200

    jman1200 http://i529.photobucket.com/albums/dd340/jmanotas/

    1,265
    5
    Nov 11, 2013
    Ontario
    Found the pic showing where the flashing tape was applied... I new I had it somewhere [CAM]

    [​IMG]20141115-01506-2 by JP M, on Flickr
     
    Last edited: Nov 9, 2017
  14. jman1200

    jman1200 http://i529.photobucket.com/albums/dd340/jmanotas/

    1,265
    5
    Nov 11, 2013
    Ontario
    They are nice indeed !
    We once rented a U-Box and they gave us 6 new ones for free, now we have too many [:D] [LOL]
     
  15. jman1200

    jman1200 http://i529.photobucket.com/albums/dd340/jmanotas/

    1,265
    5
    Nov 11, 2013
    Ontario
    Last edited: Nov 9, 2017
  16. jman1200

    jman1200 http://i529.photobucket.com/albums/dd340/jmanotas/

    1,265
    5
    Nov 11, 2013
    Ontario
    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.

    [​IMG]20141120-01568-2 by JP M, on Flickr

    The left side showing the facelifted water heater

    [​IMG]20141120-01561-2 by JP M, on Flickr

    The right side... on the top right end you can see the wires I ran to install the LED strip in the near future

    [​IMG]20141120-01563-2 by JP M, on Flickr

    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.

    [​IMG]20141120-01565-2 by JP M, on Flickr

    [​IMG]20141120-01567-2 by JP M, on Flickr

    [:D] !
     
    Last edited: Nov 9, 2017
  17. Snow

    Snow Well-Known Member

    8,805
    351
    Jul 19, 2007
    Ontario
    Looks great ... Hope to see it in person at the 2015 Ontario Rally ...
     
  18. ewils35

    ewils35 Member

    66
    0
    Oct 14, 2014
    Looks really awesome I can't wait to start mine. Ankle still hurts a bit
     
  19. jnc

    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.
     
  20. jman1200

    jman1200 http://i529.photobucket.com/albums/dd340/jmanotas/

    1,265
    5
    Nov 11, 2013
    Ontario
    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.
     
    Last edited: Nov 9, 2017

Share This Page