How to fix this broken plastic

Sbdesign

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Any suggestions or pointers?
Bit of a nightmare one.

I was thinking fine mesh on rear, melted in.
Formed to the shape best I can
Melt plastic on the top to fill
Finish with body filler.

But it’s going to be hard to get the flat top and the curved edges
 

lewinskys

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Being an AutoBody Technician, You are on the right track. But I would use a fiberglass filler. That looks like an area that is under stress and gets beat on a bit. So I agree getting steel mess in to form a profile. Fill the profile and sand, fill, sand and you can get the outside looking real good. But I think that looks like plastic rather than a fiber glass, so there may be an adhesion problem. If you do a test spot to see if the resin will adhere, you will know what the next step will be. Either continue if it adheres, or you can FORCE adhesion by figuring out the area that you are going to cover, and then you drill several SMALL holes through the plastic so the fiberglass resin can bond between the front and back. Then feather out the seam close to a curved spot to make it more invisible. There can end up being a lot of sanding to get it perfect, but spend the time to make it right. You will feel better seeing a perfect job. After the outside is perfect, I would go on the underside and build up some heavy support to take the abuse. also don't be afraid to reinforce the entire underside where you can to prevent any further breakage. Once it is shaped, a nice coat of paint over the entire piece, and it will look good.
 

Bods

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There isn't much space underneath with the metal there, it looks like the plastic rested on the metal tabs going on the left side, so it's gotta be quite thin that side unless you can lower the holster a bit to create a bit more gap so you can make it thicker

I would use Fibreglass kit for any plastic repairs myself, wire mesh on the back isn't bad idea, probably bonded on with the resin after plastic ruffed up, then you can layer the top with the resin and fibreglass sheet, can always top off with fine filler or that Dolphin glaze stuff was it someone recommended
 

Fantazia2

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Have you still got the bits or are they long gone.

If you still have them then you could use something like one of these to build it back up and then reinforce and fill with plastic.

You can also get plastic welding gear which is pretty much a soldering iron with plastic filler rods.

 

Sbdesign

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Welder coming today Chris - thought the same

Cheers everyone…
Seems I’m going in right direction…
And some good info been posted to tweak my intent!

I’m not looking for perfect, but am looking for decent…
I’ll post results
 
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