partsfe.com Opening Is your Rubbermaid plastic shed missing a crucial piece? Don't despair! Replacing the entire shed due to a single broken component can be costly and wasteful. With a bit of ingenuity and some basic DIY skills, you can create your own replacement part. This guide will walk you through the process, from creating a mold to casting a durable substitute.
Step 1: Assess the Damage and Gather Materials Carefully examine the broken part. Note its shape, size, and any critical dimensions. Take pictures from multiple angles. Gather the necessary materials:
- The original broken part (if available).
- Modeling clay (oil-based is recommended).
- Plaster of Paris or a similar casting material.
- Mixing containers and tools for the casting material.
- Release agent (e.g., petroleum jelly or mold release spray).
- A sturdy container slightly larger than the original part to create the mold box.
- Sandpaper (various grits).
- Acrylic paints (to match the shed's color).
- Clear acrylic sealant (for weatherproofing).
Step 2: Create the Mold Prepare the mold box: Ensure the container is clean and free of debris. Position the original part: If you have the original broken part, carefully position it in the center of the mold box. If the part is delicate, secure it with small supports made from clay. If only a fragment exists, reconstruct the missing sections using modeling clay. This is critical to getting a good mold. Apply Release Agent: Generously coat the original part with a release agent to prevent the plaster from sticking. Pour the Plaster: Mix the Plaster of Paris according to the manufacturer's instructions. Carefully pour the plaster into the mold box, ensuring it completely covers the original part. Tap the sides of the box gently to release any air bubbles. Let it Cure: Allow the plaster to cure completely according to the manufacturer's instructions. This may take several hours or overnight.
Step 3: Remove the Original Part and Create the Second Mold Half Remove the Original Part: Once the plaster is fully cured, carefully remove the original part. You may need to gently pry it out. Try to preserve the original part if possible. Create Alignment Points: Before pouring the second half of the mold, create some alignment points. These can be small indentations in the first half of the mold (using a small tool) to help ensure the two halves align correctly. Apply Release Agent: Apply a release agent to the exposed plaster of the first mold half and the interior of the created impression. This is CRITICAL to ensure that the halves can be separated later. Pour the Second Half: Mix another batch of Plaster of Paris and carefully pour it over the first half, completely filling the mold box. Let it Cure: Allow the second half of the plaster to cure completely.
Step 4: Separate the Mold Halves and Prepare for Casting Separate the Mold Halves: Carefully separate the two halves of the mold. You may need to gently tap or pry them apart. Be patient and avoid using excessive force, as you could damage the mold. Clean the Mold: Thoroughly clean both halves of the mold, removing any loose plaster or debris. Prepare the Casting Material: Choose a casting material that's suitable for outdoor use. Epoxy resin or a strong, UV-resistant plastic resin is a good choice. Follow the manufacturer's instructions for mixing and preparing the casting material.
Step 5: Cast the Replacement Part Apply Release Agent: Apply a release agent to the interior surfaces of both mold halves. Assemble the Mold: Carefully align and secure the two halves of the mold, using clamps or rubber bands. Ensure the alignment points are properly aligned. Pour the Casting Material: Carefully pour the mixed casting material into the mold through the designated pour hole (you may need to create one). Fill the mold completely. Remove Air Bubbles: Gently tap the mold or use a vibration tool to remove any trapped air bubbles. Let it Cure: Allow the casting material to cure completely according to the manufacturer's instructions. This is important for the strength and durability of the part.
Step 6: Remove and Finish the Replacement Part Remove the Part: Carefully remove the cast part from the mold. You may need to gently tap or pry it out. Trim and Sand: Trim any excess material from the part using a sharp knife or utility knife. Sand the part smooth using progressively finer grits of sandpaper. Paint and Seal: Paint the part to match the color of your shed using acrylic paints. Apply a clear acrylic sealant to protect the paint and provide weather resistance.
Conclusion Creating a DIY replacement part for your Rubbermaid shed requires patience and attention to detail. While this process may not result in a perfect replica, it can provide a functional and cost-effective solution to extend the life of your shed. Remember to always prioritize safety when working with casting materials and tools. Good luck!
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