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Originally Posted by john n:

I  need    to  fill  in a  1/4  inch  wide  by  3/4  inch  hole.

 Cut a rectangle of ABS or Styrene sheet stock a bit larger than the hole, about the same thickness. Since the hole is only about 1/4" wide, you might be able to simply cut a length of plastic strip stock of that width...or a bit wider.  True/smooth the patch edges.  Lay the piece over the hole and carefully scribe a line with a sharp knife point along each side of the patch onto the side of the ???...whatever.  Set aside the patch and then carefully file the opening to the scribe lines.  Try-fit the patch until it's fairly snug without buckling. 

 

Coat the edge of the patch and the hole with a swipe of Ambroid ProWeld, Tenax 7r, Plastruct Weld, et al....But NOT Testor's products (only for styrene).  (These are the types of 'welding' liquids compatible with styrene, ABS, et al.)  Press the patch into position so that it's flush to the surface or whatever is the aligning feature.  If you can approach the patched hole from the INSIDE, run a brushful of the liquid along the patch seam.  Let it dry thoroughly, say 24 hours, before sanding or painting on it. 

 

If there are gaps in the patch seam, you can apply some of the plastic putties (e.g., Squadron White or Green Putty), let it dry thoroughly, sand, (prime), paint. 

 

KD

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