Surf PI Pro Case Repair

[hobbes_lives]

While modifying my Surf PI Pro to accept a 10 cell battery holder, I made a stupid mistake and put a little nick in the black plastic case on the smooth surface right where the seal goes. It's not very deep, and is about the width of a small scratch, but is likely bad enough not to get a good seal when the case is closed. I'm looking for recommendations on the best way to fix this.

My first thought is to melt a little scrap plastic with MEK and use it as filler in the nick. I'm not sure how to get it nice and smooth after doing that though. What are your thoughts? I'm really concerned about getting a good seal after it's fixed.

(To make a long story short, I had planned to put tape on the crucial area before cutting, but then got side tracked and forgot.)

I appreciate everyone's help on this. Thanks.

 

[Old California]

Use Vaseline first, Try the clear type with no added scent. This should work and if not try using another approach.

Then, Detach housing from shaft, remove battery pack and with lid mounted back on to lower housing submerge the entire housing in a sink full of water.....While underwater rotate the housing keeping notice on the area the scratch is located, If you see any sign of bubbles leaking quickly pull housing out of water.

Question...Does the added 3 volts improve performance?

Good luck,
Paul (Ca)

 

[hobbes_lives]

[quote Old California]
Question...Does the added 3 volts improve performance?
[/quote]

The purpose of the mod is not to increase the normal operating voltage of the unit. I use NiMH cells, which run around 1.2v each for most of their discharge cycle, which is 9.6v with eight cells. The extra two cells brings the voltage up to 12v. After a full charge, the voltage is a bit higher, but not enough to damage anything.

It has been found that running the unit at a higher voltage does improve the depth by a small amount, but I wouldn't risk going over 12v purposely. Some of the components that are tied to the battery voltage are rated at a max of 15v. They could be fried if you exceed their maximum rating. Other components could overheat after extended use at a higher voltage too.

 

[hobbes_lives]

I was concerned about the various epoxies adhering to the plastic case since most of them stated that they wouldn't work on certain plastics, and I couldn't find anything locally that was made for plastic, so here's what I did...

I took a small amount of scrap plastic and put it in a jar with a small amount of MEK. After a while, the concoction turned into a fluid plastic. I took a toothpick, picked up a drop of the goo and put it in the scratch. I waited for that to set up, and then put another drop. This was enough to fill in the scratch and formed a small mound. I used an Exacto knife to shave it down until it was nearly flush. I then used a Q-tip that was wet with MEK to smooth everything out.

It looks pretty good and I think it will seal up fine. I don't think I'd take it down 100 ft., but for wading, it should be A-OK.

Thanks for all of the great replies everyone!