Plastic welding isn’t a new idea. But a recent video from [The Maker] shows an interesting twist. Given a broken piece of plastic, he secures it together with tape, machines out a channel around the cracks, and then melts zip ties into the channels. Honestly, although he mentions plastic welding and soldering, we aren’t sure this isn’t just simple gluing, but it did give us some ideas. Watch the video below and you’ll probably get the same ideas.
The ingenuity here isn’t necessarily using hot plastic to glue together two pieces — that’s just a hot glue gun, after all. Rather, it occurred to us that the key here was machining out the places where significant amounts of the hot plastic could bond the two pieces together. He cut the channels with a rotary tool, buffed them, and used a hot knife to give them some internal texture. But with a 3D printer, you could build these channels into parts that were made to interlock.
The first issue that needed sorting out was the broken case. This Amiga must have had one wild ride, as there were several nasty cracks in the front panel and whole chunks had been broken off. We’ve seen [Drygol] repair broken computer cases before, but it seems like each time he comes up with some new tricks to bring these massacred pieces of plastic back to like-new condition. In this case plastic welding is used to hold the parts together and fill in the gaps, and then brass mesh is added to the backside for strength. The joints are then sanded, filled in with polyester putty, and finally sprayed with custom color matched paint. While he was in the area, he also filled in a hole the previous owner had made for a toggle switch.
Before
After
Then [Drygol] moved onto the internals. Some of the traces on the PCB had been corroded by a popped battery, a socket needed to be replaced, and as you might expect for a machine of this vintage, all of the electrolytic capacitors were suspect and needed to go. Finally, as the system didn’t have a power supply, he wired in a picoPSU. That got the 34 year old computer back up and running, and at this point, the machine was almost like new again. So naturally, it was time to start with the upgrades and modifications.
Case fan, video adapter, and picoPSU.
[Drygol] added an IDE interface and connected a CompactFlash adapter as the computer’s primary drive. For the secondary, he installed a GoTek floppy drive emulator that lets you replace a mountain of physical disks with a USB flash drive full of images. Between the two, all of the computer’s storage needs are met with nary a moving part.
The emulator was given its own 3D printed front panel to fit with the Amiga’s visual style, and he also printed out a holder for the RGB4ALL S-Video/Composite adapter installed on the rear of the machine. To help keep all this new gear cool, he finished things off with a new case fan.
When a computer case has survived several decades from being a new toy through being an unloved relic to being rediscovered and finding its way into the hands of an enthusiast, it is inevitable that it will have picked up some damage along the way. It will be scuffed, maybe cracked, and often broken. If it has faced the ordeal of an international courier after an eBay sale then the likelihood of a break increases significantly.
After a thorough cleaning, the technique is to hold the sides of the break together, run the iron along it to melt the plastic together, and scrape the overflowed plastic back into the resulting trench before it solidifies. With careful sanding, a spot of polyester putty, and some spray paint, the broken case can be returned to new condition.
There is a video showing the process, in this case repairing a crack on a Commodore 64 case.
