Quote Originally Posted by rowhard View Post
Either way would work, but in my humble opinion, the first would be the best but the most work. You would then need to do the bodywork with primer and fillers to get it smooth enough for paint. Of course if your going to cover it in lineX or something, then maybe not.

Think I might go as far as molding in a back-up thin strip of aluminum along the seam on the underside for some strength.
Do you think it is the flexing of the insert that is causing the cracks? Or is there too much pressure on that curve in the insert? Either of those causes is going mean that your idea of an aluminum strip embedded in fiberglass on the bottom of the insert would help to prevent the cracks from returning. The expanding of the crack and refilling it with resin and glass fibers would also help to hold everything together. As far as LineX on the insert, I have not decided whether I want to that or not.