I wanted to give you my approach to fixing this problem.
I've done my research and read about repairs involving glue, plastics, epoxy etc... I'm sure they are just as good, but I wanted something sturdier.
NOTE: This repair strategy will not work on all of the TABS of the door.
Some of the tabs, like below, have "misaligned" screw holes to the tab, so it won't work.
If you happen to have a broken tab that is aligned with the bracing piece screw, then you can attempt this repair.
Here is an example of one that ISN'T broken, but could theoretically be fixed in this fashion.
Here is my problem piece. The plastic crumbled as I was removing the door panel to get to the speaker box.
another view:
side view:
Now on to the repair: I wanted to use something with additional bracing and support. I decided to use a piece of pipe brace.
Trial #1 was with a copper -T-shape pipe wrap - Home Hardware store - $2.15
Align and bend it as necessary to get the shape all right
clearance was checked, close but far from perfect
This is the tied down screw of the perimeter and as you can see, there is a slight curvature that needs to be replicated for a perfect fit
Unfortunately, I was unable to get the alignment 100% correct for the bottom piece that needed to be bolted down
The metal was too thick and difficult to bend precisely.
I'm sure some of you could actually get this to work with thicker metal
So I abandoned the procedure with this type of metal.
Trial #2 was with some more malleable routine pipe fitting that you find in the plumbing supply section.
cost: $0.93
same procedure as above - much easier to manipulate the metal, the screw holes lined up perfectly and were very strong.
another view
all you need to do now is paint it black (if you want). It secured up nicely and overall, was a tight perfect fit.
I can assure THIS tab will never break again. Good Luck!
I've done my research and read about repairs involving glue, plastics, epoxy etc... I'm sure they are just as good, but I wanted something sturdier.
NOTE: This repair strategy will not work on all of the TABS of the door.
Some of the tabs, like below, have "misaligned" screw holes to the tab, so it won't work.
If you happen to have a broken tab that is aligned with the bracing piece screw, then you can attempt this repair.
Here is an example of one that ISN'T broken, but could theoretically be fixed in this fashion.
Here is my problem piece. The plastic crumbled as I was removing the door panel to get to the speaker box.
another view:
side view:
Now on to the repair: I wanted to use something with additional bracing and support. I decided to use a piece of pipe brace.
Trial #1 was with a copper -T-shape pipe wrap - Home Hardware store - $2.15
Align and bend it as necessary to get the shape all right
clearance was checked, close but far from perfect
This is the tied down screw of the perimeter and as you can see, there is a slight curvature that needs to be replicated for a perfect fit
Unfortunately, I was unable to get the alignment 100% correct for the bottom piece that needed to be bolted down
The metal was too thick and difficult to bend precisely.
I'm sure some of you could actually get this to work with thicker metal
So I abandoned the procedure with this type of metal.
Trial #2 was with some more malleable routine pipe fitting that you find in the plumbing supply section.
cost: $0.93
same procedure as above - much easier to manipulate the metal, the screw holes lined up perfectly and were very strong.
another view
all you need to do now is paint it black (if you want). It secured up nicely and overall, was a tight perfect fit.
I can assure THIS tab will never break again. Good Luck!
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