Kinda Urgent: Thule box repair Bad cracks

[Micol]

I tried ...

what i did was similar to what u suggested. but instead of dryer sheets i have stainless screen, instead of epoxy i have melted abs welding sticks. all in all pretty much same as your suggestion but beefier outcome. this box is xl and 32 “ wide and heavy. i needed bulletproof as a yard sale would cripple my ski season. and because i’m chasing pow it’s not a short route from home to the local hill to retrace…. it would be i lost my best skis somewhere in the last 500 miles. my truck has like 700 mile range and i don’t stop much. also travel a lot in dark. and yes 700 mile range on 30 gal tank getting 24+ mpg

[MakersTeleMark]

You must have a third tank for your piss.

[Micol]

i got 3 tanks for that

over 180 ozs

[Talisman]

Micol travels astronaut style!

You must have a third tank for your piss.

[Micol]

carrying everything but oxygen

[XXX-er]

what i did was similar to what u suggested. but instead of dryer sheets i have stainless screen, instead of epoxy i have melted abs welding sticks. all in all pretty much same as your suggestion but beefier outcome. this box is xl and 32 “ wide and heavy. i needed bulletproof as a yard sale would cripple my ski season. and because i’m chasing pow it’s not a short route from home to the local hill to retrace…. it would be i lost my best skis somewhere in the last 500 miles. my truck has like 700 mile range and i don’t stop much. also travel a lot in dark. and yes 700 mile range on 30 gal tank getting 24+ mpg

sounds like BS

[Micol]

^big sky?

yep i hit that

[Micol]

put the product description sticker back on for good measures and camoflauge...

[XXX-er]

what i did was similar to what u suggested. but instead of dryer sheets i have stainless screen, instead of epoxy i have melted abs welding sticks. all in all pretty much same as your suggestion but beefier outcome. this box is xl and 32 “ wide and heavy. i needed bulletproof as a yard sale would cripple my ski season. and because i’m chasing pow it’s not a short route from home to the local hill to retrace…. it would be i lost my best skis somewhere in the last 500 miles. my truck has like 700 mile range and i don’t stop much. also travel a lot in dark. and yes 700 mile range on 30 gal tank getting 24+ mpg

what you did was exaclty like we suggested except entirely different

cuz epoxy sticks to whatever you put it on while plastic is just going to fall off,

half a doz of us suggested dry wall tape or fibreglass cloth but it looks like what you really wanted to do is play with your plastic welder and the finished product kind of looks like ass with those big heat marks

so much drama, so much big sky

[Micol]

^ yeah, yeah... lets say epoxy is like dog shit. and my boot sole is teh box. i step in your dogshit. the dogshit is on the sole of my boot. eventually that shit is going dry up and fall off the sole of my boot. maybe this week, maybe in 5 years. but eventually it falls (cracks). however, if bull shit is abs plastic strips, and those bull shit strips gets melted into a molten mass and it becomes the actual sole of my boot not just a clingon, it never falls or flakes off. instead of a 1" original sole with dogshit hanging on it, i have a 1.5" sole of pure bullshit. not a dogturd stuck to the bottom of my boot. get it ? i drink your milkshake , drink it up !


and that dryer sheet.... it 's like my dog ate a sock and then that got shit out and stuck to the boot sole first b4 the turds .....

jsut saying.....many ways to skin a bull, so im going to follow the butcher

[MakersTeleMark]

You have a dog?

[SumJongGuy]

Needs stickers

[Micol]

i have a bull

[Micol]

Needs stickers

💯



,

[MakersTeleMark]

I have a shit.

[Micol]

if it with soul

[MakersTeleMark]

[Micol]

Positive Use Report: 2200 miles and she stayed together. high winds, warm temps down to 10 deg, snow, ice , sometimes driving 80 mph, opening and closing adding and removing gear throughout the trek ..... no evidence of any movement or change to the repair. I ditched the factory product sticker @ first fuel stop

[waveshello]

I got a steal of a deal on a damaged Thule roof box (Force XT? XXL?) at the habitat 4 humanity this week. $49. All the hardware is present and accounted for, including key, and it functions perfectly. Score!!

My plan, which incorporates some of my lessons learned from a previous repair and advice in this thread, is as follows:

- Drill ends of cracks to stop propagation (done)
- Use heat gun to relax plastic so edges can be mated together. (Done)
- Join edges that are closely fitted with same stuff plastic welder
- Tape exterior, apply gflex epoxy from the inside to fill larger gaps and holes

I haven't decided if I'm going to lay up some fiberglass on the interior, or form some 1/16" abs to essentially create a patch behind the crack that I can gflex in place.







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[Micol]

^legit work !

update on mine....i parked my truck with some valet in vejas while running dual boxes.....mf'er took it into 2nd floor of parking garage and ripped both beyond any repairs....i did get a check but major inconvenience.... that check was for replacement cost tho lol.....moral of story no good repair goes unpunished....and yeah, what happens in vejas stays in vejas , boxes in dumpster there....


yo, xxx'er aquaseal to isle 9

didnt hurdt my skis either.... bg's and fat lhasa's tough m'fers

but yeah , bummed got 3 months out of my repair....due to valet operator error

[waveshello]

No good! Sorry to hear it. I guess that box wasn't going to get away with cheating death.

I made some progress on mine, I got the plastic welder in the cracks to join them back together, then applied the gflex and glass. I'll do the other side tomorrow... And use a little less epoxy.



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[Micol]

^ that looks good imo

[Wes Mantooth]

No good! Sorry to hear it. I guess that box wasn't going to get away with cheating death.

I made some progress on mine, I got the plastic welder in the cracks to join them back together, then applied the gflex and glass. I'll do the other side tomorrow... And use a little less epoxy.



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What exactly did you do here? I have a similar situation cheap box that needs a small repair exactly like this. Don’t have a plastic welder and don’t really want to buy one so wondering what I can get away with using just tape and g flex (if anything)

[XXX-er]

yo, xxx'er aquaseal to isle 9 ]

fuck ya plastic welder you got this

[snoboy]

Feather the edges of the cracks down a little to make a groove. Drill matching holes on either side of the crack, stitch each pair together with SS wire. Grind up ABS pipe and dissolve in acetone to make a thick paste. Apply as much as required to both sides. Multiple layers may be required. Going on probably 10 years now?

pic upload no longer seems to work for me...