Quote:
Originally Posted by BrianG
Didn't read the whole thread, so this might have already been mentioned, but if you need a longer tray, simply cut one in half and spread them apart. Chances are you only need no more than 1", and a gap that big is no big deal.
And instead of cutting out a notch for the wires (which weakens the tray), consider putting in a dense foam spacer in the big enough to allow room for the wires to exit.
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Some of the boxes are quite wide (depends on length) but the overlapping cut uses much of it for the bottom plate. Mostly the end walls are cut out.
The notch really does not weaken it if you cut it right. Don't cut at the exact corner, and don't go all the way to the bottom. Putting the notch in the rear is advisable, as most crashes are head on. As described, I use a small scrap and cement it in on the end to overlap the cut in the wall, so here the tray is ~.25" thick. Its quite tough, even with a notch.
I have yet to break any boxes even after a couple years of abuse. The only one that came apart is one I tried to use testor's ABS model cement (for models) as my plumbing ABS had dried out and I didn't feel like going to the store. Glue did not bond the same, and only lasted a few crashes.