Sanyo m9802 cassette door plastic repair

dan

Member (SA)
I ended up busting a plastic piece on a sanyo m9802 cassette door. I tried gluing it with gorilla super glue and even jb weld plastic weld but it broke again the moment some pressure went on the part while putting it back on the boombox.

Any recommendations? Is this part polystyrene? I've heard maybe melting the parts together with heat? Or fusing with acetone?
 

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goodman

Member (SA)
This is an unpleasant problem...
Try to put and glue an additional piece on the back that covers the base and the broken part if possible...
 
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Superduper

Moderator
Staff member
On vintage boomboxes, almost all of the plastic parts can be repaired with acrylic solvent cement which fuses the parts as the solvent actually temporarily re-liquifies the plastic allowing fusion. Once dried/cured, the parts should be as strong, or nearly as strong as before the break. However, newer plastics use a different formulation and does not respond to the acrylic or pvc cements like vintage boomboxes. You can typically find these cements from places like tap plastics. Luckily, the solvent resistant forms of plastic is a newer concoction and most boomboxes respond well to this type of repair.

However, that being said, this form of solvent cement repair should be attempted first because in my experience, once other types of adhesives are tried, (such as superglue, jb weld, etc.), they contaminate the surface and reduces the chance of a successful solvent repair. Stripping off the residue can reduce the original plastic making fitment of the joint poor. Remember, solvent cement has no fillers so it needs a good fit.
 
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dan

Member (SA)
I had tried bracing the side with a strip of clear polystyrene plastic from a cd jewel case. It looked promising until I tried to push the door back on. The pressure snapped the brace and it broke. I don't know if the glue makes the brace piece brittle or if it's because such a short piece of polystyrene can't flex much before snapping.

Then I said, I'll just live with one door stop. Tried to push the other back in and it broke off too.

I'm experimenting now with nylon tie strap. I've glued a couple of pieces to a jewel case. After 4 hours of curing, they are pretty stuck and surive hard tugging. I left some strap to pull from. Only thing is, the glue joint doesn't survive peeling the strap away or twisting the strap. Mind you, I didn't leave it for a full 24 hours to cure but I expect the same would happen.

I got a black nylon tie strap just as wide as the plastic piece that's broken. I'll give it a light sanding, I'll cut it to length and gorilla super glue it on as a side brace. The nylon tie strap is flexible enough that the repair should survive the door reinsertion.
 

dan

Member (SA)
Actually, I'm scrapping the superglue idea. I've been testing with using hot melt glue, black nylon tie strap and a clear poly styrene jewel case and I'm having good results, gluing the ribbed side of the tie strap. The ribbed side makes for better adhesion, vs the smooth side. Can't do that with super glue because it doesn't like gaps.

It's withstanding pulling force, twisting, etc to a good degree, better than superglue. The force I'm using would have broke the original part. These are regular surebonder glue sticks. I've ordered tough stik and best stik to see how those hold up compared to the regular one.