Just got done repairing my PO cab that had some nasty damage right in the curve of the control panel.
I started off by cutting out the damaged area, once I removed all of the flaking wood and old filler I was left with a pretty ugly scar. I squared off the area and cut it clean. Then matched a new another piece of wood and glued it in place. I added 3 dowel pins between the new piece and the cab to add stability and help hold the piece in place. Once the glue dried I was left with the image below.
The closest size plywood I could find at home depot without going any larger than the cab was 1/2 inch. I figured I could make it work and fill the rest with bondo to make up the difference in thickness.
I was worried the piece may wiggle from side to side if hit the wrong way so I decided to reinforce it with some staples on each side. I routed out an area equal to the depth of the new wood and started stapling it up. From the inside the staples will be covered up by a piece of wood that retains the monitor plexi.
I started off by cutting out the damaged area, once I removed all of the flaking wood and old filler I was left with a pretty ugly scar. I squared off the area and cut it clean. Then matched a new another piece of wood and glued it in place. I added 3 dowel pins between the new piece and the cab to add stability and help hold the piece in place. Once the glue dried I was left with the image below.
The closest size plywood I could find at home depot without going any larger than the cab was 1/2 inch. I figured I could make it work and fill the rest with bondo to make up the difference in thickness.
I was worried the piece may wiggle from side to side if hit the wrong way so I decided to reinforce it with some staples on each side. I routed out an area equal to the depth of the new wood and started stapling it up. From the inside the staples will be covered up by a piece of wood that retains the monitor plexi.


