Help me spitball: city lid repair

[punkassjim]

Hey folks. I bought a set of city lids for my system cases a few years back, and one of them had cracks in the plastic around the latch brackets. Didn’t take but a year for both of the latches to snap right off, cause there really is no good way to shore up the mount without a) compromising some structural integrity, and/or b) drilling through the outer face of the lid. Anyway, here’s what I got:





So I was thinking of using some 1.25” box tubing, cutting it to the right bracket shape, snug-fitting it between the plastic tangs that remain in the lid, and putting one or two rivets through each side to anchor the new bracket to those plastic tangs. I’ll need to be very precise with the fit, because any tension or flex on those remaining plastic tangs is just gonna snap them off. And I can’t decide if I can get away with just one rivet per side; it’ll be more likely to rotate, which could put additional stress on the plastics, whereas two rivets will preclude rotation, at the expense of one more hole to further weaken each plastic tang.

Anyone here got structural engineering experience? Have any better ideas to fix this thing? I’d hate to throw an otherwise pretty lid in the garbage.

[hellfishtat]

drill some small screws through the metal latch, but not though the lid, and maybe through the sides of the plastic. Fill the entire void with 2 part epoxy

[boxerebel]

Yup working to resolve the same problem . I'm reinforcing with epoxy resin (use gel magic) or JB weld and some fibreglass cloth or mat. Be sure to take a torch (lightly) to the surface to assure good bonding. ABS slurry might be the better treatment . Resin/cloth is kind of nasty.
Also I found the lids to be a bit hinge bound putting undue pressure on the latches. I am going to slot the hinge points and give more clearance there. Can't get city lids any more.

[boxerebel]

Also consider installing a partition insert part #s 01 46 542 316 913
01 46 542 316 914
These allow you to cram more stuff in the bottom of the bag without stressing the hinges and keeping your gear from falling out

[punkassjim]

Originally Posted by hellfishtat

drill some small screws through the metal latch, but not though the lid, and maybe through the sides of the plastic. Fill the entire void with 2 part epoxy

Oh that’s quite a good idea! Helps shore up the whole thing. Thanks!