"How To" repair Pelican case's evil style....

Discussion in 'Equipment' started by EVILONE, Jan 10, 2007.

  1. EVILONE

    EVILONE Long timer

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    I had mentioned in another thread that I would document how I went about repairing a pair of Pelican case's I bought cheap on E-gay a few days ago.Be warned now that this is lengthy,and pretty detailed.This will be a 3 part documentary,the first section will be about repairing the holes,the second about refinishing them,and the third will be about building some racks and mounting the cases.So with that said,here goes.

    I got the cases today,and this is how the arived,[​IMG]

    They were dirty,so the first thing I did was clean them with a de-greaser,and then some dish soap.Be sure to rinse them very good,and let them dry.This one is now clean and ready to work on......[​IMG]

    Here you can see one of the many holes that need to be repaired before they can be used.[​IMG]

    [​IMG]

    The next step,is to rough up the inside area where your repai work will be done.I used a die-grinder with a 36 gril roloc disc to get the surface lower than the rest of the area.I strongly recomend you use saftey glasses,and a paper mask,the dust in your mouth sucks![​IMG]
    more.................
    #1
  2. EVILONE

    EVILONE Long timer

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    after getting the surface beveled doen a ways,I then used ome 80 grit sandpaper to remove all the fuzzy edges.I have all the air tools to do this job,but hand tools and elbo grease will work too,its just slower.[​IMG]
    after the 80 grit,I wiped the repair areas with a solvent cleaner.......[​IMG]

    After the cleaner drys,the next step is to spray "adhesion promoter" to the areas that are getting repaired.Allways start the repair with the the back side of the repair area.I used the 3-M automix system,and before 3-M will warranty the repair,you must use 3-M adhesion promoter(part#5907).It is in a spray can,and a light coat is all you need.[​IMG]
    more.......
    #2
  3. Bob

    Bob Formerly H20Pumper

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    What kind of bug in the background?
    #3
  4. EVILONE

    EVILONE Long timer

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    next,I pre cut some reinforcement patches,(part #4904).The patch needs to overlap the hole by 1/4 to 1/2 an inch......[​IMG]

    after all the patches are cut to fit,I then tape up the front side of the holes,so that when the bonding matterial is applyed,it doesnt run out the hole,do this to all areas to be repaired............[​IMG]


    now you are ready to apply the reinforcement patches.The are sticky on one side,so stick them where you need them.Only holes larger than a dime need the reinforcement patch,but if you can kill two birds with one stome,why not.[​IMG]

    [​IMG]

    more to come.....
    #4
  5. EVILONE

    EVILONE Long timer

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    I then applyed the 3-M semi rigid plastic repair(part #4240).You need a special gun to use this stuff,but they are cheap,and once you know how to use this stuff,you find all kinds of uses for it.the work time on this stuff is pretty fast,so I didnt get any pics of me applying the product.I just put more than Im going to need on,because I can allways take some off after it drys.While it is still workable,use a spreader to push it past the reinforcement patchand flush with the tape on the outside.[​IMG]

    [​IMG]

    Leave the tape on the outside!If you try to remove the tape before the product is dry,it pulls the product threw the hole you are trying to repair.

    After about 15 minutes or so,(depending on the temp.)you can remove the tape on the outside,it should look like this......[​IMG]

    [​IMG]

    more on the way.....
    #5
  6. EVILONE

    EVILONE Long timer

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    dont worry if there are some pockets where the plastic repair didnt get all the way to the tape,im gonna cover that.You can see that I had allready prepaired the outside of the repair.It makes no diffrence,you can grind and sand that area before,or after the plastic repair product,I just figured,while I was there I might as well grind it.

    The outside needs to be "dished" out about 1/8 of an inch,and thats when you can clean up any product that might have broken throug the tape.[​IMG]

    a pic of the "gun you need.....[​IMG]

    after doing any grinding/sanding that needs to be done( I allways go over the areas that I uaes the grinder on with 80 grit)you are ready to apply the finishing coat to the outside.To stay within the warranty,I used 3-M E-Z sand plastic repair.Before you apply it,you must put a light coat of the adhesion promoter on the areas you plan on puting the E-Z sand.The work time on the E-Z sand is fast as well,so again,I didnt get any pics,but I allways put mor on than I think Im gonna use......[​IMG]

    after I apply the E-Z sand,while its still workable,I mash it down in to the cracks with a spreader,than try and smooth it out,[​IMG]

    more to come.........
    #6
  7. EVILONE

    EVILONE Long timer

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    It takes about 15-20 minutes to be able to sand the E-Z sand.I use that term lightly,because it is anything but,however,it needs to tough,so I guess its a fair trade.I start off with 80 grit,and finish it off with 180.I also use a dual action sander,especialy when it doesnt have to be perfect,and these dont.the end result should look something like this......[​IMG]

    [​IMG]

    [​IMG]

    After you have it the way you want it,and all the "edges" have been "feathered out",apply one more coat of adhesion promoter to the finished product.Whay you ask,Im not sure,but 3-M says to,and I have found if you follow 3-M's directions,you rarely go wrong.Now its ready for primer and paint,but that will be another section of this project,and another night.

    I am in no way saying this is the only way to fix these holes,but in my oppinion it is the best way.I own a body shop,and work with plastic often,so I thought I would share some of my know how with you guys.
    Hope some one can use the info I posted.....

    EVILONE:evil
    #7
  8. DirtDOG

    DirtDOG Same Dog, New Tricks

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    You dolt, you didn't answer the VW question.

    [​IMG]
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  9. EVILONE

    EVILONE Long timer

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    lol....good point,I was tryin to focus.....its a 70 or 71 I think.The pics I could show ya of that thing....lol

    EVILONE:evil

    P.S......when you gonna come get your cat DirtDog?:rofl
    #9
  10. toolfan

    toolfan Broken Hearted

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    Nice work. Nice shop too.

    Can you buy the reinforcing mat seperate, or does it come with the other stuff? How much did that set you back?

    I was going to give mine a go tomorrow night, but I was going to try using JB-stik, which is a putty/clay like product made by jb-weld. It was "product of the month" a while back in motorcycle consumer news, so, we'll see how it goes.
    #10
  11. EVILONE

    EVILONE Long timer

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    Thanks toolfan!
    You can buy all the matterials seperately,I dont know how much it would cost right off hand,but I will check tomorrow and let you know.I have never been a big fan of JB weld products,but I would love to know how your project turns out.

    EVILONE:evil
    #11
  12. RaiderSix

    RaiderSix R6 commuter.

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    Is that an '81 Malibu? :D
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  13. WestRider

    WestRider Been here awhile

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    I was planning to use a fusion stick welder with PP sticks but that looks like a great way to make those repairs. I'm a long way from needing these cases...like months....so I've got a bit flexibility. Do you have to buy those materials from a commercial supplier or can you get them at retail places too?

    :lurk :lurk :lurk


    #13
  14. EVILONE

    EVILONE Long timer

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    I dont think you can get these materials from Autozone,or anything like that,but your local paint and body supplier can get them for you,if the dont allready have them in stock.Worst case,you could order it straight from 3-M.

    EVILONE:evil
    #14
  15. EVILONE

    EVILONE Long timer

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    nope,......79:deal

    EVILONE:evil
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  16. scooteraug02

    scooteraug02 Dog Rancher

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    Nice post. I was watching the Pelican thread about the purchase.

    3m 5887 $33.99 click here

    3m 5907 $21.99

    BASF 901 Couldn't find a price.

    Duramix 4240 $28.44 click here


    Special gun $69.99 Click here


    Duramix Dispenser $43.99 Click here


    So if one gun does both you can get all that stuff for about $100.

    What do you paint the Pelicans with? This is great. Finding info on plastic is as topsecret as automatic transmission info.
    #16
  17. toolfan

    toolfan Broken Hearted

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    Hmm...
    tube of jb-stick - ~$5.

    I'll let you know tonight if it works. I'm planning to do three total, but two of them can wait until next week sometime.
    #17
  18. EVILONE

    EVILONE Long timer

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    Scooter,I only have one gun,so I would think all you need is one.Im not sure how Im gonna paint the cases yet,but im either gonna spray on bedliner,or paint mine flat green.There is a secret to the paint part too,and Ill let you know when the time is right,(mabey this weekend).....lol


    EVILONE:evil
    #18
  19. WestRider

    WestRider Been here awhile

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    Thanks for the info...for those of us without all the goodies and who don't do this for a living...I did a bit more research...

    Duramix 4240 is also availalbe as 4040 in a 6oz tube that doesn't require the gun and the EZ Sand is available in 5oz repair kits...no gun required...at least that I can find.

    I found the 4040 for $23.28 from http://www.detailandstripes.com/40duseplre04.html

    and the EZ Sand for $29.75 from (same place actually) http://store.goferauto.com/3mauezsaflpa.html

    I also notice that Harbor Freight has a plastic welding gun for about $40 with a pack of plastic rod for $6...but that might not work very well for the large holes without some patch material.

    Hmmm...don't know how excited I am about spending $60-$100 to fix a set of $20 boxes...maybe those simple patches are looking better all the time....I'm glad there are lots of options out there!!


    #19
  20. cuneesity

    cuneesity Ferendo

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    I can't wait for the third installment about the racks:clap :clap :clap

    What kind of bike are you mounting to? And if it is and LC4 chassis would you like to build two?:evil :evil
    #20