On disassembly I found some cracks in the plastic dashboard of the Diablo Rouge. Upon further inspection I determined the crack could be fixed by plastic welding. I have done this method in the past with ATV and dirt bike fenders with success. The plastic welder is made by the urethane supply company. It consists of a heating element and some plastic filler rods. Here is the method I used:
1. Plug in the iron
2. Clean the repair area with wax and grease remover and let dry completely.
3. Clamp the dash to restore correct alignment
4. With the iron hot groove the plastic the entire length of the crack.
5. Fill in the groove with the iron and filler rod.
For this repair I just did the backside and it seems to be strong enough. I didn’t like the way this repair looked when completed and I didn’t want it to show on the front side. Leaving the front side alone will look better. If this was an ATV or dirt bike fender I would do both sides since they flex more. I have had mixed results as to the look of the repairs. Some blend in very well and some don’t look so good. It could be the old age of the dash or a different plastic than the filler rod. The box advises that different material filler rods are available but I have not tried them. I have tried other methods of plastic repair like glues and drilling and stitching and have found that the plastic welding method is stronger and looks better than these methods. The repair turned out well – it is strong, looks better than before, and new cracks in the same area will be avoided. I can get a replacement dash for this sled but it is expensive so the repair route was an easy choice. Just another day in the shop.