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The original locking/rotating mechanism on a four by six foot dry erase board was made of plastic. The board weighs about a hundred pounds and stress on the "ears" when the board is rotated caused them to break. |
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Super glue, Bondo, putty and injection wax are used on the broken part to make the pattern. |
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Since only one casting is needed, we used hard injection wax to fill the screw holes in both parts of the pattern. Wax is too fragile for a pattern that will be used many times and the screw used to lift the pattern chews up the wax. Since the wax is self leveling, it leaves a nice smooth surface in the casting making it easier to accurately drill holes. |
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A flex shaft sander makes short work of smoothing the Bondo. The underside of both sides of the patterns were also beefed up with Bondo and wax. |
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