You might want to think about repair vs purchase.
I recently took the overlay off my 172 and did many major repairs. I
had many cracked corners and missing bits and pieces.
For the cracks I used epoxy and a little bit of fiberglass to
reinforce from the back.
For small missing areas, I used bondo to build up the areas.
I had one hole that had been converted from a 3 1/8 round hole to a
ATI square hole for my STEC autopilot. Whoever installed it had used
a heater to melt the overlay and sort of bent it into a semi square
shape. It really looked like hell. To fix this, I made a square plug
to match the hole I wanted in the overlay, pushed it into the space on
the overlay, and packed bondo into the spaces between the plug and the
overlay. Later, I removed the plug and faired up the corners.
For large messed up areas, I bought a used panel on ebay for spare
parts and cut and pasted with fiberglass as needed.
To finish, I used a faux granite paint from the hardware store for a
base coat. This provided a really nice texture that is just slightly
rougher than the factory part. This stuff will cover up any minor
imperfections or differences in surface roughness. After the base
coat, I used a gray vinyl paint from the auto parts store. To finish
it up I bought engraved placards from a sign shop to replace the
original decals.
For loose wobblely post lights that won't stay lit, I used little bits
of aluminum tape on the sides of the bulb inserts to tighten them up.
I spent about $50 in parts (and maybe $2,000 in labor at my normal
hourly rate of $2 / hour.) Although it took some time, the end result
is an overlay that I thinks looks way better than new.
Jeff
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