Changes from my previous post. 1) Brass piano wire (1/32in) available from Hobby Lobby can be used instead of the paper clip. 2) Piano wire can also be used to reinforce the front suspension struts which we saw break on Steve’s car 2 weeks ago. 3) The plastic in the AllSlot chassis bonds better with epoxy (JW Weld, JB Quick) than with superglue/CA.
Fix broken guide bosses with (a) a brass tongue from Professor Motors commercial parts section, $4/ea, and (b) one thick and one medium B-Nova adapter.
Steps: Dremel the old guide boss to be level with the top of the chassis. Flatten the center ridge also. Glue a thin B-Nova adapter to the tongue; use this as a template to grind down the brass flag-pole shaft ring to be as thin (appx 1.5mm) as the B-Nova. Test the rotation and widest swing with a Slot.It CH07 wood guide. Grind out a notch in the tail of the tongue (4mm x 6mm) to allow the front chassis screw to be accessed. When finished the thin B-Nova can act as a guide spacer – useful for the old style chassis w/o adjustable axle. Leaving the rest of the tongue full width adds strength to the lower suspension struts. Epoxy the tongue, B-Nova down, to the bottom of the chassis. Epoxy the thick B-Nova to the chassis and top of the tongue, using a toothpick to add epoxy to the small gap between the B-Nova and the tongue (at the flagpole tube). Rub a clean toothpick on the inside of the flagpole tube to smooth out excess Epoxy in the tube. When dry use a razor knife or small round file to remove excess epoxy from the tube; test with the CH07 guide to make sure you do Not remove too much material and make the boss too wide!
Check the height of the stack with a CH07 flagpole-use a thin or medium B-Nova to add height as needed. Epoxy to top of thick B-Nova. The total thickness of the B-Novas+tongue should be appx 6mm.
TISSUE PATCH: Steve recommends a quick, light and strong fix using a small piece of tissue, doped with CA just like putting a fibreglass patch on a 1×1 car. Cut the tissue to a little larger than the crack, with a 1/6 to 1/8in skirt. Smear a small bead of CA along the crack, then use a toothpick to tap the tissue onto the damaged area, smoothing out the tissue. Add more layers of tissue for a severe crack; but in most cases 1 may be enough. When dry add a 2nd layer of CA making sure all of the tissue is doped. When dry, trim excess only if needed.
"... get on your bad motor scooter and ride!"
Sammy with Montrose