Drastic Plastic: Enclosure Rebuild Uses Donor Material

Although 3D printers are great, people tend to use them as a universal hammer wherein almost everything becomes a nail that’s just begging to be struck. So as hacker appetites become finicky with the same old fare, it’s refreshing to see an enclosure restoration done in such an old-school fashion. To wit: [Doidão Santos]’ classic repair of the crumbling side fairings on a vintage amplifier.

Yes, instead of designing replacement pieces, printing them, and hiding the layered evidence with paint or an acetone blur, [Doidão] called upon a broken sound system whose chassis bore a relief in the corners similar to that of the amplifier.

After cutting out two matched pieces of donated plastic, [Doidão] taped them together and welded ’em with a soldering iron outfitted with a curved-but-flattened spade tip that looks ideal for this purpose. Although the donor enclosure provided much-needed relief, one corner was lacking in this aesthetic, so [Doidão] cast a little bit of molten plastic using the relief as a mold.

Once the pieces were tacked together, [Doidão] filed them down, sanded them, polished them to a nice shine, and installed them on the amplifier. They look great, and no one will be the wiser. But if we were in [Doidão]’s shoes, we’d tell everyone what we’d done. Be sure to check it out after the break.

Ready for more fantastic plastic resto-hacks? Let us introduce you to [drygol].

Thanks for the tip, [danjovic]!