Repair to damaged front panel of Datron 4808

[perdrix]

Before I acquired my 4808 it suffered damage to the front panel



Has anyone experience of repairing this type of damage, and if so what products will do a good job?

Thanks lots
David

[dnwheeler]

Check out this YouTube video for a more extreme case (a shattered Atari 800XL):
The results aren't great, but your case is much simpler. The basic idea is to create a mold of the texture (from a good area), then use that and fill it with epoxy to replace the missing area. Then finish and paint as desired.

[branadic]

If you don't want to fix it, but replace it you could reconstruct the panel in a CAD program and send the CAD file to a chineese company to make a vacuum PU mold, a 3D-printed part both including textures or a cnc machined aluminium part and powder coat it, which should give similar results of the surface.

-branadic-

[pbarton]

I have never used it myself, but I have heard of good results using 'Sugru'.
https://sugru.com/

[coromonadalix]

Sugru +1    you can slowly sand it, and fit it to your frame,  when its dry

[perdrix]

I sprayed the opposite corner of the panel with "mould release agent" and then applied silicone sealer in an attempt to make a negative mould.

It appeared to work fine until I tried to remove it only to find that it had stuck like crazy to the plastic panel (you'd almost think I'd not used a mould release agent).

So I need to get some silicone remover gel and try again.    What do I need to do to get this to work?


Addendum:

I found this: https://www.wikihow.com/Make-a-Silicone-Mold

So I'll try the soap/silicone trick to 3/4 cure it before starting the process.



Thanks
David

[George Edmonds]

Hi David

Use a very small drill to make holes to insert bits of steel wire into damaged area to provide a good key (paper clip bits) and then repair using P38 sand and repaint.  Will not be quick to do a good job but it can be done and made invisible.

73 George G6HIG

[MadTux]

Some epoxy with cotton fibers to thicken/strengthen it and perhaps some styrofoam as molding material
Sanding/grinding and new paintjob afterwards and it should look as new.

[perdrix]

I successfully made a mould of the diagonally opposite corner using the technique of "squidging" the silicone sealer in a jug of warm water with some washing up liquid in it to partially cure it before use.



Used a soldering iron to add some 0.8mm stainless wires to provide reinforcement.

Then sprayed the mould with mould release, taped it to the damaged corner and poured in a mix of polyester resin and white pigment (RAL9010) with hardener.



Will update when it's fully set and I've taken the mould off (fingers crossed).  I hope the pink from the catalyst goes away!

Cheers, David

[perdrix]

Hmm... The pink didn't go away, and the result wasn't as good as I hoped.  I did some patching and then textured the surface with some Isopon P38 car body filler. The result isn't perfect cosmetically, but I went through all my colour charts trying to find a good colour match for the original plastic and failed.



So I've decided to leave it as is, as I don't really wish to re-spray the whole thing.

David