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Zenith SupersPORT Case Repair

thenzero

Experienced Member
Joined
Feb 19, 2021
Messages
430
Location
Perry, GA
So I recently bought this zenith supersport from ebay. It works flawlessly but the case was broken pretty badly during shipping. You can see in the pictures that a structural part of the case was completely unattached. I am trying to source a replacement case to rehost the internals but in the meantime I thought I'd try to repair the case at least enough to be usable. After some research I settled on using friction welding with ABS filament. It worked way better than I expected. Thought I'd share the method and the results in case someone else was interested in trying it. Basically you cut a 1.5 inch or so piece of filament and slot it in your dremel. Spin up and apply along the crack. For parts that had a large hidden area not accessible with the welding (like the bottoms of case screw supports) I supplemented with super glue before welding along the outside edges. When I was done I cleaned up they visible areas with a hot knife and then some light sanding to make it prettier. It's not meant to be aesthetic but it doesn't look terrible considering. With some practice I think you could make this look pretty dang good.

See the attached before and after pictures.

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