brunnhilde's cassette toilet - part 3

This is the third installment of converting Brunnhilde's toilet to the cassette type.
I planned to complete the exploration deep dive for a go/no-go decision of the conversion using option 3. Option 3 involves modifying the existing shower pan in situ.

Warning - some image may be offensive

Yesterday I removed the existing toilet to have a better look of the sewer stack connecting the toilet to the black water storage tank. So far so good and I didn't find anything I am not already know. I was hoping to be able to see the thickness of the shower pan but was unable to without cutting out the toilet flange. Seeing the thickness of the pan will give me some idea the effort required to cut it cleanly in situ.

The other exploration is to find the bond strength and compatibility of epoxy resin with the what appears to be ABS shower pan. Today I dug out my collection of fiberglass material. Unfortunately it drizzle all day here and the high humidity is not the best environment to work with the epoxy resin.

last time i worked with fiberglass must be 15 years ago - shelf life, what is that?

 found the bag of s-glass remnants - i know why i cannot ever throw anything away

i inspected the bottom of the old toilet to find a good spot for testing the bonding of the epoxy and fiberglass to the ABS shower pan

 this (orange spot) is a good spot for doing the test in case i want to abort the project

Thinking ahead about how to cut the shower pan. The most obvious is using a rotary abrasive wheel. As I don't want to damage the shower wall or the subfloor it would be a time consuming task. It would also create a lot of harmful dust. Because the shower pan has slops there may be a bedding compound between it and the subfloor. Removing the scrape portion of the shower pan may require a lot of effort and may require breaking it into small pieces. All these are unknown until I start.

I wonder if fein multimaster would make this really easy. It should for cutting the ABS plastic. It would not help with the bedding if it is elastic like caulking. Many time I entertaining of buying this tool...

fein multimaster

I need to cut an access port on the bathroom back wall for the waste water caddy (cassette) access. To cut it cleanly it would require building a router guide. Also there may not be enough space to be able to get the router close enough for the area adjacent to the Sprinter side. I ordered this optional door kit when I ordered the toilet. It is used on a lot of European campers and motor homes for utility door installed on the vehicle's exterior.

The door would fit nicely on a range of thickness. In my case the ply wood cutout would be reused as the door insert in this kit, leaving a factory look. The European James Cook does not have this door. It just has an opening with plastic edging as found in most Westfalia cabinets.

you even comes with key least your precious black gold get stolen

update may 19:
Must be my male's instinct of tool hoarding, the allure of a shining new tool is beckoning. I have been wanting a Fein multi-xx micro-displacement vibration tool for over 2 decades but always been able to complete my projects without one. These days there are a lot of copycat products (i infer due to the expiration of the pattern(s)). Fein's sales hardly suffered because it continue to innovate and maintain the uncompromising quality.

Fein has a full line of professional tools and cutters built on this innovation from a few decades ago. Seems they are doing a thriving business on many fronts, especially the auto-glass segment in which they have a range of specialty blades for cutting flexible adhesives with surgical precision (Fein's vibration tool was built on surgical equipment that first used this tool innovation).
fein's professional set for auto glass - if you have to ask how much, you cannot afford it

For a consumer like me it seems this much cheaper kit would be the best choice.
fein's current consumer grade combo kit - if you have to ask how much, you may be able to afford it (circa $299 on web)

The attachments for the pro-line and the consumer line are not interchangeable.