whats the best product and or method for repairing cracked plastic?

I can't really answer your question but I had the idea to use a fiberglass repair kit to fix the cracks and weak spots. Actually I wanted to go over the whole plastic part with fiberglass, then sand smooth and paint. Seems like it would be pretty strong that way as long as it will bond. Other than that I've seen plastic welding kits, don't know whats involved. good luck.

From what I have seen, for small cracks, use zip ties to stitch it up. For large cracks, put a backing behind it (like sheet metal) and then either stitch it or rivet the piece to the backing.

They sell plastic welding devices search the net for them
http://search.yahoo.com/search?_adv_pro ... &fl=0&n=10

IMO if your going to stich the plastic buy some safety tie wire
http://www.brookfieldwire.com/lockwire.htm
Only drill a hole big enough for the wire to fit through it will look better than using plastic ties since the stiching is smaller, the safety wire is stainless steel so don't rust.

I'm less than an hour from Brookfield.
There is some ATV riding near them.

Has any one actually bought from them? I'd be interested in a small spool.