Damaged corners

roothorick

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We have three different machines with this type of cosmetic damage. I'm just curious, how do you guys handle damage like this? Obviously you can glue the T-molding back down, but what about the chunk missing out of the board?

 
To be of a little more help here, just use bondo to build it up and then use a router to cut the groove for the t-molding. Depending on how big of a chunk is missing you might also want to put in some wood screws and build up the bondo around it to help give it some more support. Do a search on Bondo here and you will see some examples of peoples work and see how it can turn out.
 
I've got a couple cabs with damage like that... and while the word on the street is bondo... I never understood why, with larger breaks like that, a dove tail wouldn't work better? Is the wood just too weak to support that?
 
Im sure a dove tail would work great to but not everyone has the woodworking skills or the equipment to do that. With bondo all you really need is a sander and a little time.
 
Personally I'd square the corner off, use a biscuit joiner to put another piece in to replace the missing wood, then use the opposite side as a template to cut it back to the original shape. Then redo the T-slot and use Bondo to hide the seems.
 
Personally I'd square the corner off, use a biscuit joiner to put another piece in to replace the missing wood, then use the opposite side as a template to cut it back to the original shape. Then redo the T-slot and use Bondo to hide the seems.

bingo, bondo is for smoothing things out not building things up.

if you wanna glob it up with anything, make a stencil of the other side 2x
put wax paper on them, tape them on and fill them with duraglass.
its much stronger than bondo.
 
Bondo is wonderful stuff but I don't have a lot of confidence in it when used in huge, thick, load bearing amounts. IMHO I'd try to use as much actual wood as possible and use the Bondo to hide imperfections. Duraglass/fiberglass is really tough stuff also, but you'll need Bondo to hide it too!
 
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