I spent today finalizing a repair to the articulation on my Ge 6/6 II "Scuol". Don't ask how it got broken!
. I've got no one to blame but myself
. I'm just surprised how little damage was done after falling about 3 feet onto my patio's concrete pavers.
After opening up the loco to assess the damage I decided to approach the repair in multiple steps. I glued the broken piece of the frame circled in the photo back in place with ca adhesive. I did this about a week ago. So the glue had plenty of time to cure while I waited for some part 2 epoxy to arrive - a West System™ Gflex 650 Aluminum Boat Repair kit. This kit includes epoxy and a strengthening filler that can be added to thicken the mixed epoxy.
This next pic gives some idea how the two frame halves are attached together.
I roughened the area to be epoxied with coarse sandpaper and also drilled a number of small holes through the frame to give the plastic some "tooth". I then cleaned the area with acetone where the epoxy was to be applied. The area between the stiffeners molded into the frame.
Next I mixed up a batch of the epoxy and "wetted" the repair area with un-thickened epoxy. Some of the thickener was then mixed into the epoxy. The thickened epoxy was smeared on the repair area and used to create fillets for the molded frame stiffeners.
I allowed this to partially cure, about three hours, till the surface was still tacky but some of the bumps could be smoothed. Then I laid on some fiberglass matting I had on hand from another job. The fiberglass was wrapped around the repair area to the underside of the frame.
The tackiness of the partially cured epoxy held the fiberglass in place until it could be wetted out with a freshly mixed batch of epoxy. I laid on two more layers of fiberglass while I had the freshly mixed epoxy available.
I probably should have waited a couple of hours between fiberglass layers but impatience got to me. The more I tried to smooth the epoxy impregnated fiberglass the uglier it became. I decided to quit while I was ahead. The epoxy will take about two days to fully cure. I'll see where things are then. Hopefully, the loco will be ready for re-assembly without too much further work.