Morgans wrote:

My tactic for splitting plastic cases is to use a dremmel tool with a
thin cut-off wheel, and cut right on the seam. Don't bother trying to
pry it apart, since they always crack like you have observed. When
putting it back together, I use JB Weld on the seam and quickly put
electrical tape over the seam. This holds the case together while the
JB sets up and the tape will later peel off, leaving a nice slick seam
of JB. On a black case is difficult to see that it has been taken
apart, since the JB Weld becomes a smooth surface that matches the
plastic case amazingly well.

I have used this method to replace cells in power tool battery packs,
and the repair holds up to the extreme abuse they are subjected to.


I was already predisposed to believe the efficiency of this method.
Scaled up to an angle grinder with a thin cut-off blade (which are
amazingly rugged these days) I have opened an impromptu inspection
panel in a car door to replace the electric window winder clutch,
saving a whole bunch of hand wriggling in a narrow door space;
Carved a notch in a big bale carrier strut to put the load further
forward (If you ever had 1200 lbs of hay trailer wriggling a truck
like a girl with a hula hoop, you'd want to do this...) and cut off
a sink drain stopper funnel securing ring, long since corroded
to immobility. I am a believer!

Brian W