Wow... Just checked back on this thread, didn't know I had started this whole thing with my question... I didn't want to make this about DJI and the quality if their products, I was hoping for some advice on how to fix the cracks I have on my drone... Warranty or not, I have no intention to be sending it in and wait months for my drone, I will go the DIY route and glue it, if the shell gets any more damage I'll replace it, anyone here who has used epoxy on their bird and has had any negative impact on behavior? Thanks!
That's a good choice IMHO. I am currently performing some experiments on a few P3 shells and maybe I can help with some tips. This is fun work, you'll learn a few tricks and develop skills that can be used in other areas too!
I have a friend's already cracked shell fixed with epoxy and patches of Kevlar (taken from bike tire puncture-preventive strips like SpinSkinz for instance) judiciously cut and glued to the motor area, arms and core; and another new one with strips of 2x2 3K carbon fiber twill cloth reinforcements also glued to the inner part of the lower shell also using epoxy. Both are flying for about a month, lots of flights in various conditions, and both are doing very good. No cracks- not even signs -, no issues, 100% normal performance in flight. Added weight is about 30g, if much.
From your picture it seems like the shell integrity has been compromised, and repairing it can be quite a challenge. The P3 body is essentially a monocoque assembly which basically means the shell is the functional structure of the aircraft. Minor cracks can be fixed and stopped and the whole thing can be strengthened but only to a point. Tolerances are quite small on the shell and it may be hard to keep integrity and strength while maintaining alignment of parts, especially in the motor base.
The best solution in this case would be to buy a new shell which is quite cheap and perform some kind of preventive reinforcement of the arms and tips (motor base). If done right can be a definitive solution for cracks. Some say Plast Aid, Bondic, or other epoxy based glue or something. IMHO any good one will work if correctly used. You can find carbon fiber, glass fiber and Kevlar starter kits on eBay, Amazon and others, with everything you need and simple instructions. There's no need to exaggerate just a bit of correctly applied resin and maybe some fiber or cloth to help keep integrity and give some flexibility to the reinforcements should work.
I took some pictures but can't find the MicroSD card used since I keep changing cards on my P3 and camera but if it's lost I will do it again, I'm fixing another cracked shell for a friend and have another new one waiting to be reinforced too.
Good luck!