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hacked up wood control panel - repair it or junk it?

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Ken Layton:
Krick said he didn't have the tools to make a fresh one. I've seen panels that were a hundred times worse than what he has now. I've built hundreds of control panels both from scratch and repairing used ones. The one Krick has is one I'd repair. Bondo and a sanding block is what he needs.

SirPeale:
Ah yes, missed the proper tools part.

Well, in that case, what I have done in the past is to use a C clamp to hold a flat piece of wood against the top of the panel, and then fill the hole with Bondo.  Of course, you will need to 'key' the hole somehow, otherwise the bondo will pop right out.  Once the hole is filled with Bondo, 'squeegee' the bottom so it, too is more or less flat, and wait for it to cure.  You shouldn't have to prep the top much, if at all.  The bottom you may have to scrape a bit down to make it flat.

Stingray:
Those holes are too big. Filling them with bondo is just asking for trouble.

-S

NoOne=NBA=:
If it were me, and I HAD to fix this, I would probably:

1) Clamp the top to a smooth board (as mentioned above).
2) Fill all the holes from the bottom side with Bondo.
NOTE: Keying the fills by grinding the holes larger on the bottom side would help.
3) Sand the bottom side smooth, and level, to the existing wood.
4) Put a piece of 1/4 plywood across the bottom using contractor's glue.

The ply on the bottom, coupled with the plex on the top should prevent the bondo from breaking loose.
I would really recommend keying them, and would still try to place the sticks in the wood if at all possible though.

Worst case scenario--this doesn't work, and THEN you have to build a replacement.
I would hold off on doing any replacement graphics, until you have thoroughly tested the longevity of any repairs you do though.
If it does break, you'll only be out time, and a little money that way.

crashwg:
First thing you should do is find out if there is anyone on this board who lives anywhere near you.  Having a lack of tools on this board isn't so much of a problem if you just ask for help.  Most people would have no problem letting you come over to chat about the old days, drink a beer and cut out a piece you need withe their router.

Of course if you don't feel comfortable doing that, I'm sure you must know somebody that has a router or saw.  Most people don't go arround wearing a sign that says "I have tools at home"  so you're gonna have to ask arround.

In case you couldn't tell, I'm against the repair of the old CP, it just seems like it would be more trouble than it's worth...

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