[Gooserider]

1. Replacing the cracked box w/ a non cracked box is the best repair.

2. Any time you are dealing with a crack, if you don't want the crack to continue to spread you should 'stop drill' at the END of each crack. This is when you take a drill (usually ~ 1/8") and drill a hole at the very end of the crack. This relieves the stress the crack is making and prevents it from spreading further. However this only works if you drill at the very end of the crack. (It is OK to fill the hole w/ sealant afterwards)

3. It is best to use plastic fittings in plastic holes, however you can use metal fittings if necessary. Just use lots of sealant and avoid excess torque as reccomended earlier.

4. The optimal glue for repairing (if you must, remember that replacing is better) is one that does solvent welding. Putting a layer of silicone over any repairs won't hurt, but ONLY if the stuff you are using has excellent adhesion to the box material, and if it is rated as suitable for constant water immersion. On any kind of glue, surface preparation is CRITICAL, follow manufacturers surface prep recomendations carefully.

Gooserider