A little mechanical excitement

[Stichill_imp]

If we lived in the post apocalyptic world of Mad Max, with no reasonable alternative, I would suggest thorough cleaning, duct tape the hole outer surface, pour liquid steel or some such into the cavity, Let dry, remove tape, cross fingers, and go another gazillion km.

Ben

That's the way to go! I would add 1-2 bent stainless steel paper-clips to give more stability, like iron in concrete.

But then, that's probably German uber engineering again...

Ha! I did something like this on my BMW. A plastic tab on the fairing snapped off. I took some copper nails, cut the heads off, and flattened them with a hammer. Then I embedded them in epoxy as reinforcement across the broken section. Worked great, probably stronger than new! And, less than the USD $575 cost of a new plastic panel.