One of the things on my 'to do' list following our recent jaunt to Northumberland was to fix a crack that I'd noticed in the door opening to the cupboard below the wash basin. From the muck in the crack it must have started some time ago and been quietly spreading without my knowledge.

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From the location of the crack it can only have been caused by downward pressure from the edge of the shelf insert. So here's the warning - don't put anything heavy on this shelf as the same thing may happen to you. I had been carrying two bottles of toilet concentrate in there and I reckon that that's what did it.

The first thing to do with any crack in plastic is to stop it spreading further and you do that by drilling a small hole at the end of the crack.

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My first attempt at a repair involved some brass shim material and pop rivets - too flimsy, then with a piece of plastic card (ditto) and to complicate matters further it was difficult to get the head of the riveter into the confined space.

After much scratching of head and cardboard template-making, I found a piece of old aluminium alloy angle from which I cut a repair piece to go under the damaged edge. Self-tapping screws seemed the best way to fix the alloy as I felt sure that any adhesive would be bound to fail with the constant vibration while towing.

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It took a bit of experimentation with drill sizes before I got it right and could drive the screws through the alloy but the end result seems very strong and should do the trick.

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With the door closed, little of the damage is visible but I now need to experiment to see if I can find a filler that will hide the crack.

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Incidentally, it is surprising how much unused storage space there is below the plastic shelf in the cupboard and I'm now thinking of how best to use it; tools and toilet chemicals perhaps?

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Yes, I know it needs a good clean, but when was the last time you looked under yours?

Quote: Aaron Calder wrote in post #1

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...I now need to experiment to see if I can find a filler that will hide the crack.

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Quote: Pepé Le Pew wrote in post #2

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If you felt so inclined you could make your own by dissolving bits of ABS (white Lego is ideal) in acetone.

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