General Chest light cut out incorrectly

I just recently purchased a Fettronics light board for my chest armor, but now have a dilemma concerning the cut outs for it. When i bought my Boba, the cut outs were already there, and a sticker of the chest lights were there as a placeholder. Using a caliper, i measured the cut outs to be as follows: (Top hole): 5mm tall, 64mm wide (Bottom hole): 9mm tall, 64mm wide. According to Fettronics, the height is correct, but the length is only supposed to be 50mm wide! The cut outs don't appear to be the most evenly cut holes ever, and the gap in between the holes is only 4mm, when Fettronics calls for at least an 8mm gap! What should I do to correct this? Any ideas would be greatly appreciated!

I would put something sturdy secured to the back, and bondo over it and maybe use some sortbof shims to keep a straight edge against the opening youre keeping. That's how I've filled major holes with some things. I'm sure there are other ways. Just my two cents

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I had a similar problem, but from adapting the cut outs from WOF's templates to my armor -- short story the first cut out was in the wrong position! I used JB Weld (a 2-part epoxy) to fill the old cut out, then re-cut in the proper position. There was some overlap, but JB Weld is awesome (I've used it to fix cuts in my car's radiator that held for years) and there was no problem with weakness. I roughed up the plastic with sandpaper first, then used a clear tape over the outside of the cut out (to hold the general shape while applying the epoxy and curing), filled the gaps with the epoxy, slightly overlapping the cut out on the inside of the armor, and let it dry/cure overnight. After smoothing the outer surface again I was able to cut out the slots for the lights. The thing I like most about JB Weld over bondo is the work time -- you have an hour or more to spread it, and can carefully shape with wet toothpicks or fingertips, whereas my bondo experiences were tragically short and messy. After the painting, you can't tell a thing, and the former cut out areas are probably stronger than the original ABS!

BobasDent1138 said:

I would put something sturdy secured to the back, and bondo over it and maybe use some sortbof shims to keep a straight edge against the opening youre keeping. That's how I've filled major holes with some things. I'm sure there are other ways. Just my two cents

Sent from my SAMSUNG-SM-N910A

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This is the way to go. Bondo is your friend