Post by hailrazer » Sat Aug 30, 2008 7:24 pm

I started out like I mentioned wanting a SOLID handheld. So I decided to try a technique not used much.For plastic if you use normal epoxy and Bondo spot putty, it can and usually will crack.So I used ABS Cement to fuse the parts like the screen, controller, etc to the case. Then I used Plastic Bumper Epoxy Hard filler to fill major gaps and fuse it together even more. :Then I use Plastic Bumper Flexible Filler as the "spot putty" to finish it off smoothe and crack free for life.Please note in the following pics I decided to abandon the white piece and add the controller later.The process is pretty easy. You cut the parts for as close a fit as possible. Then put a spot or three of hot glue to hold the part in place. Tape the backside of the case for large gap areas. The I use a cue tip , dip it in the Abs cement and drip it in between the two parts. It adheres pretty quick. I let it dry in front of a fan for an hour then do it again to fill in missing gaps. Let it dry about 2-3 hours, flip it over and remove the tape and then using the cue tips drip in the Abs Cement REALLY thick on the backside. Now let it dry for a couple of days.After a couple of days sand down the Abs plastic on the front side with 36-40 grit sandpaper until it is smooth and level, don't worry about low spots.Now it's time to move on to the hard filler. Mix it and apply it liberally in the areas you need to fill and mold. It dries in 15 minutes and you can sand it down. Use 36-40 grit paper and sand it down real good and as smooth as you can get it.To be continued.............