Filling a plastic hole

[steeleygreg]

Gentlemen, I need to replace the plastic bracket which supports the manual climate controls on my 240D. I removed the old broken one and have another to replace it. In removing the pop rivets holding the bracket to the evaporator housing is where I messed up. Now I need to fill 1/4 inch holes with something which has enough tinsel strength to hold screws.
My first thought was use fiberglass filer mixed with kitty hair, but I'm looking for any viable solution short of using 3M 5200 to hold it in place. Any suggestions ?

[BoiseBenz]

I would try using a wood nail, heated in the torch flame, or a soldering iron to melt some of the base plastic back into those holes. It's likely polyethylene or polypropylene, both of which are used as the BOTTLE for the other glues--nothing bonds to them.

If you try your standard plumbing-pipe ABS solvent and that works, then you can cut off "excess" material from elsewhere on your bracket and solvent-bond that over your holes.

[whunter]

Rivet it back on if possible.

PVC cleaner and glue is a possible option.

Small lag bolts will work, if they won't puncture the heater or evaporator core.

pictures would really help.

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[qwerty]

Originally Posted by BoiseBenz

It's likely polyethylene or polypropylene, both of which are used as the BOTTLE for the other glues--nothing bonds to them.

There is a two-part epoxy putty designed to repair cracked battery cases that will stick. It can be shaped or drilled once it cures. Amazingly tough stuff.

Originally Posted by steeleygreg

Now I need to fill 1/4 inch holes with something which has enough tinsel strength to hold screws.

A Rivnut can do that.

[panZZer]

Two part epoxy and 2 layers of window screen wire lammed into it
Real window screen-Not plastic
your regulator got sent out today-Thanks

[steeleygreg]

I like the Rivnut idea. I researched this and it's probably the best controllable option. Although I did consider panZZer's idea with the screen and glass. Currently I used polyester fiberglass resin mixed with fiberglass strands. This is called kitty hair. Some patches held and other didn't. I'm new to working with polyester resins so I would either mix in to much hardener and cause it to cure to fast, or didn't put enough hardener in the mix which resulted in something that never hardened completely. My experience is solely with epoxy resins. In repairing any fiberglass repair, it is imperative that the bonding surfaced be roughed up with something like sand paper to cut through glassing and maximize the bonding area. In a small space like where this bracket goes, it's not that easy.
The glue idea I originally had and the 3M 5200 is used in the marine industry just for the purpose of gluing two objects together, just never try to take them apart. Since this is a keeper vehicle I'm going to try the Rivnut idea. I want the option of being able to take it apart if ever the need arises again. I'll supply pic's tomorrow.



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[whunter]

No pictures of the before - after???


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