Fix Cracked Sill - 996?

[jcsjcs]

Hey All - I cracked the Sill on my 996 and need to repair it. The crack is right on a corner and the pieces fit together well. I plan to pull off the Sill and repair from behind.

Any recommendations on how to proceed? What kind of epoxy (?) should I use? And should I use something behind the crack to reenforce?

Any suggestions on how to proceed are appreciated as I am totally new to this type of repair.

[962porsche]

pull the rocker cover off the car to get to the back side.
clean the back side with something like simple green and hot water.
then wipe down the area and about 4 inches past the damaged area with isopropyl alcohol.
sand with 80 grit sand paper and again 4 inches past the damaged area.
clean again with the isopropyl alcohol.
with masking tape . tape and hold the parts back together as it should be when not broken.
cut a piece or two of the drywall tape like shown in the pic's.
you want the tape to to fit the contour of the part with no wrinkles or bumps in the tape.
so cut the tape as need to do so.
put the tape to the side and using SEM 68422 plastic repair mix and then spread a tight coat over the back side of the damaged area.
stick the tape back on the damaged area and using a body filler spreader or putty knife push the drywall tape into the SEM plastic repair.
once the tape is pushed into the SEM spread another thin coat over the repair.
let it sit and don't screw around with the part once it dries then pull the masking tape off the outside of the part and clean up any dried ooze out you may have.
you can do this with a utility knife.
you can kind of see how it is in the pic's of the back side boats engine cover.
the engine cover is SMC plastic so the color of the repair product for that is black.

[jcsjcs]

Thanks! I may do that for the curved portion that is most visible (from the back of course). I also ordered some polypropylene and a “plastic welder” to ser if I can fix some of the non-visible parts…. More to come.

[jcsjcs]

I did not do this nearly as well as @962porsche recommended and ended up using a Plastic Welder from Amazon (which is essentially a soldering iron with a triangular tip.)

I was inspired to do this by this video from @hallvardr on his YouTube Channel.
https://www.youtube.com/watch?v=sj3QWmbyAGU&t=1s

Originally Posted by hallvardr

I have made a YouTube channel that will follow the ownership of my 2002 996tt.

The sill was very cracked in places and using the plastic in the kit AND some included stainless mesh, I was able to get everything back together and in pretty good shape. There is a very small gap on the corner, but I decided to leave it since it is backed by repair plastic and mesh. I did not want to mess with the corner more since it is very visible. Everything else is not.

At some point I will probably replace both sills - but this should hold me for a while.

Kit I used:
https://www.amazon.com/Massca-Plastic-Reinforcing-Professional-Portable/dp/B07ZPGJH1V

I do need to refresh the plastic - any suggestions?

Pics below....