Thanks for the message, I found the conversion relatively easy. You will need the following tools and materials:
Bosch multi tool or dremel with cutting discs
Brass piano hinge
pop rivets
small washers
small lock with keys
spray paint
large fibreglass kit from Bunnings
duct tape
oil
paper and masking tape for spraying
First, put the pod on a flat surface and decide where you want the lid to go in relation to where you want it to open, get the duct tape and lay it carefully around the outside of the pod, then carefully cut the pod using your cut off tool, i used the bosch multi tool, then use a fine sandpaper to sand the rough edges down.
Next get the brass hinge, i had to cut it down to fit neatly. Drill corresponding holes from the hinge to the pod, use a pop rivet with a washer on the inside of the pod to distribute the weight and reduce the chance of the hinge and rivet failing.
Once the hinge has been fastened you need to use the duct tape again to reattach the lid to the pod securely in the position you want it to be in before you start fibreglassing.
Go to bunnings and get the largest fibreglass kit you can get, i think its the 1kg bucket about 50 dollars and you have everything in it to do the job.
Next get the duct tape and attach it to the inside of the lid only as you need the lid to come away after the fibreglass has set, i put a touch of oil onto the tape and spread it all over prior to mixing the fibreglass.
Get some coarse sandpaper and rough the inside up so that the surface is keyed to take the fibreglass.
If you've not used fibreglass before don't rush... first you need to cut the fibreglass sheet up into 4 equal pieces, then with each piece put it inside the overturned pod, you will have to cut away some of it to fit comfortably, i cut the corners to allow for the sides, cut all 4 pieces first. Next mix up about a sixth of the resin with the recommended amount of hardener, once you start its best not to stop.
Work in a well ventilated area and don't smoke, the resin is flammable and smells. Also wear gloves.
Place your first piece of mat into the pod and with the brush, use a stippling action to put the resin on. i tried a brushing action but the strand came away.
depending on how much or how little of the resin mix you have made up you may need to put another strand mat on next or mix up another batch of resin, continue putting the mats over each other until you have 3 mats layered, i think this is sufficient although you could get away with two, three is just slightly thicker than the original pod thickness.
Then keeping the pod overturned, leave the fibreglass to set for 24 hours this is quite hard as the anticipation of seeing whether your hard work has payed off.
After 24 hours and the fibreglass has cured, strip the duct tape off the outside, and gently prise the lid away, strip off the duct tape underneath and clean thoroughly.
I then used masking tape and newspaper to mask off the areas i didn't want painted, then with a can of spray paint with thin coats evenly spray the areas, its easier to put on lots of thin coats than to spray hard and end up with runs everywhere, again leave to dry.
Then with your cut off tool, open the lid and on the new fibreglass mark out your opening and cut out, i left high sides and a bit towards the back for the lock to hook onto.
Get your lock which should be around 20mm in diameter, using a spade bit find the centre of the pod on the outside of the lid and calculating where the locking arm will come, drill the hole, clean up the rough edges and fit the lock, I had to bend the locking arm slightly in a vice to get it to latch properly.
And thats about it.
If you have any further questions, mail me back
Happy to help
Pete
