From: John Eifert [JohnEifert@hotmail.com]
Sent: Monday, March 19, 2001 1:42 AM
To: 928
Subject: [928] Chin Spoiler Repair for "S"

Just checked up on the repair of the chin spoiler I did this evening.  The
spoiler was actually broken in two pieces at the outboard side of the
brake duct.  I came up with this repair after originally thinking about
fiberglassing the break, and my experience with a quick set epoxy.

My repair took a piece of "Bondo" brand self adhesive repair patch (a 6" x
6" perforated aluminum sheet), and cut a section to match the contour of
the area on the back side of the spoiler underneath and to the side of the
brake duct opening.  Then I took two #8 x 3/8" stainless steel screws and
screwed them through the perforated sheet metal into the backside of the
spoiler about @ 3/8" out from the outboard side of the break towards the
top and bottom of the patch.  The screws will pass through the spoiler
exposing the tips of the screws.  The exosed screw tips were later be cut
off and finished flush the front of the spoiler.  I then secured the outer
edge of the patch on the same side of the break with two more screws.  The
two spoiler pieces were joined together two more screws were used to
secure the patch to the spoiler @ 3/8" in from the inboard side of the
break, and one more screw to secure the narrow inner edge of the patch
underneath the brake duct opening.

With this done the spoiler is fairly rigid.  However, the break in the
flange for bolting on the spoiler still allowed movement.  Fot this I took
a quick set epoxy and worked it into the break of the flange and then
built up a layer of epoxy on the top and bottom of the flange.  The
spoiler was set into position and the epoxy set.  At this point the
spoiler had much of the rigidity of the unbroken side.  To add more
strength to the repair I mixed a large portion of quick set epoxy and
spread it over the patch, working it into the perforations to fill any
gaps between the patch and spoiler and effectively epoxying the patch to
the spoiler.  The quick set epoxy cures to a hard plastic consistency and
the spoiler has the same rigid feel on the broken side as on the non
broken side.

As stated earlier, the exposed screw tips were cut off with a "Dremel"
tool and the crack and screws were covered with "Locktite" black plastic
rubber.  I am looking for a paintable rubber or something similar to try
to bring the finish close to original.  The rubber dip used for coating
tool handles was suggested in a tip on Greg Nichols list, and I am going
to test it on the back side of the spoiler.

All of the materials were found readily available at a local auto store
and the screws were purchased at a hardware store.

I will post some pictures when I get my digital camera back and figure out
a finish coat.

Regards,
JE
1983 928S AT US x 2
928OC
PCA
Rennlist