My dad helped me repair my radio surround earlier and it's like a brick house now. Just wanted to share his method. Maybe it will help someone one day?

What you need:
1) Toilet paper or paper towels
2) Super glue
3) Epoxy
4) Dremel (to sand everything smooth)

For the non-visible side, hold your broken pieces together and spread a little super glue over the crack. Tear a long strip of toilet paper and put it onto the super glue. Make sure to completely cover the toilet paper with super glue. On the visible side, put epoxy over the crack to cover it up. Let everything cure over night. Dremel the epoxy smooth and paint it. Simple enough.

Reason for the toilet paper is more or less like a lame version of fiberglass.

 

great tip.

 

This is archive worthy.

 

Nice tip, do you have any pics of a before and after?

 

Back in my RC airplanes day, there used to be a product that was used with superglue as a lightweight gap filler; was basically tiny glass bubbles that you'd shake/pack into the the gap then wet with CYA glue. Dried like a rock, but was very light (mostly air) and somewhat sandable. Kind of a poor man's aerogel.

 

i agree....uh..we need pics of this

 

Unfortunately technology has it's limitations. I have no more camera batteries.

I'll describe it to you the best I can. On the backside it's nice and rough just as you'd expect so I just covered it with epoxy for that extra good bond. I didn't spend a lot of time on the front so it's a little rough but one section I repaired was smoothed all the way down just like the crack never happened. As soon as I get some batteries, I'll post some pictures.