I've been working on the kit and thought I'd share some update photos.
After getting estimates on repairing the damage to the shells, I figured I could save a few bucks by doing the bulk of the prep work myself. It's been fun and a good learning experience.
Stripping the wrap was the first lesson. I tried a heat gun, but ended up pulling back a bit of the top layer of mahogany on the bass shell, despite going really slow. I then regrouped and applied a liberal amount of paint stripper to the wrap. That did the job perfectly, as I could slide a putty knife underneath the flexible wrap and it peeled off beautifully.
My plan is to fill the damaged parts of the outer mahogany with bondo. (I know, it sounds weird, but I've used it on wood before and it works well.)
Filling the extra drill holes was pretty straight-forward. I just got a bunch of dowel stock in different sizes and glued bits of those in. Once dry, I ground them down with a disk sander to get them close to the shell and finished them off with a palm sander.
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The tricky part was filling the gaping holes in the floor tom and bass drum. The floor tom had suffered some heavy damage by the muffler. Using a router, I cut out the damaged section entirely, plus a bit extra from the mahogany on the top side.
[img]http://farm6.static.flickr.com/5070/5590622569_767a5d147d_t.jpg[/img]
I had a heavily damaged spare shell that I cut a section from and then shaped a matching plug by hand and glued it in.
[img]http://farm6.static.flickr.com/5063/5591214600_41e90b3aef_t.jpg[/img]
I hadn't done this before, and it worked out pretty decently. I still need to give the interior part of the repair a skim coat of bondo to cover the grafting seam.
[img]http://farm6.static.flickr.com/5098/5590625957_8fa73d169f_t.jpg[/img]
[img]http://farm6.static.flickr.com/5097/5591217968_4f4482cb24_t.jpg[/img]
I'm in the process of doing the same thing with the bass shell where someone mounted an after-market center stand for a double tom set-up.
The rack tom and snare required a lot less work. I filled some minor holes on the rack tom and retro-fitted the snare to take a baseball bat muffler, as opposed to the earlier type that it came with. I gave those two shells a coat of KILZ primer and hand sanded them to smooth over the dowels. I'll go back and give them a second coat/sanding and then will paint them to emulate the original white finish.
I'm hoping one or two more weekends worth of work and all the shells will be ready to send off for new BOP wrapping.
As always, thanks to all who have offered advice/tips. I'll post more photos as progress merits.
John