1989 Ski-Doo Repair Manual, Page 569Get this manual
Section 07 BODY FRAME Sub-section 01 IBODY)
Remove the C-clamps and run bead or weld down the center of the crackTo assure strong repair also run an overlapping bead of weld on each side of the first oneBe sure that the break is completly welded, especially at the endsIt is also possible to repair broken headlamp bracketcab hinge supports and large breaks where pieces of the cab are missingFor broken hinge supports, remove the hinge and cut piece from sheet of polycarbonateVee the bottom of the nerw hinge support and groove the cab in the position where the hinge seatsInsert the hinge, tack in place and weld several beads around the base of the hinge for strengthIn the case of large breaks where pieces are missing, cut piece of polycarbonate sheet to replace the missing piece and weld it in placeMethod of finishingTo finish crack on the exterior of the cab, begin by running the tacking tip down the cracle to make shallow groove(Do not use grinder, only the taCking tip)- Lay single bead of weld down the groove made by the tacking tip- After the weld cools (approximately 15 minutes) use body file to file the weld smooth with the cab material- Hand sana with fine grade paper to remove any scratchesBuff with rubbing compound then polish with polishing compound