As mentioned in an earlier entry, I need to make a security screwdriver to enable me to open an old battery charger that was broken.
One of the chaps on the Blokeyshed forum pointed out that this was potentially dangerous and that the makers probably put those screws in place to stop people opening the case. There is a reference in the manual that this device should only be repaired in a certified repair centre. I understand this but as I’m not planning to change the circuitry I thought it was a fairly low risk activity.
Opening up the case I saw that two of the posts for holding the screws had broken off.
I wrapped some masking tape around these and filled the resultant tubes with an epoxy plastic material.
Once this was dry I drilled the holes and used a cutoff disk to trim the top down. The material was good to work and cut well.
At this point all I had to do was to screw the case back together. However because my driver had a big handle on it I managed to overtighten it breaking my new plastic additions from the case (which I was not happy about). It is possible that there was an issue with the bond between old and new plastic, I probably make the posts thicker if I tried this again (taking care not to obstruct the electronics)
I did manage to bond the plastic parts with some superglue and once dry screwed the screws in. Now the case is back together and can be safely used.