Gentlemen!
As promised, a quick update to my experiments.
I'm sure some of you have seen the YouTube vids about ABS-slurry.
Basically, you take some scrap ABS plastic, and dissolve it in acetone (50g to 125ml).
This results in a paste-like substance (a bit thicker than wood glue).
Using a syringe and blunt needle, this can be used to fill out cracks and small gaps.
Using a (cheap) brush, it can be spread over larger cracks if they can be accessed from behind.
The material dries hard, waterproof, but not very flexible.
I've used it so far to patch a few cracks and build up material (using multiple applications) on some weak parts.
I WAS hoping I would be able to "cast" parts using it, but it does shrink while curing, so accurate casting is tricky.
Also if the layer (or block) is too thick, it takes a LONG time to cure.
Summary: not great for casting, but good for crack repairs.
Use a CHEAP brush, because it becomes useless after this gunk gets in it.
Maybe have a few repairs set up at one time :-)
Methinks 3D printing will be the way to go.
Cheers
James