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Repairing a metal CP
dcsgguy:
well I partially fixed it last night. I bought some jweld and these metal strips that weren't as small as the plugs but they should work. I attached those to the back then bondo'd the front. I'm going to sand it today and see how it came out.
Crowquill:
http://www.multigame.com/cp.html
This is the best Info I've found on patching metal panels. I don't know why it doesn't come up more often. It seems most of the emulator cabinet crowd just wants to replace it with wood and the people doing restorations either aren't talking or just buy a new panel.
When I was patching mine I found a variation on this tutorial that I followed. I used epoxy to attach some metal plates that you find in the same aisle as the electrical boxes and outlets at the hardware store. After that, just fill with your choice of materials. I actually filled mine with Elmer's wood filler. Strange as it sounds, it actually lists metal as one of the materials it can fill. Probably not hard enough for a game that would be on location, but for my home use it's fine (and cheaper and easier to work with than bondo).
Tailgunner:
I've filled extra holes in my metal panels by grinding fender washers to fit and then TIG welding them in place. I used to fill the 3/16" bolt hole in them with bondo, nowadays I'll back it up with a piece of copper bar and weld the hole up.
If you go that route and all you can find are zinc plated washers, you can eat the zinc off with muratic acid leaving a plain steel washer. You can buy small quantities of muratic acid in the tile section of building supply places, it's used for cleaning tile grout. Wear gloves/goggles, it's not super strong acid but it will burn you if you get it on your skin.
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