Hi, Colin.
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I guess I have to file down the remainder of the old screw wells to be flush with the surface of the case.
Yes, leveling the surface will lead to wilder contact surface.
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Any suggestion on how to ensure exact alignment of the plastic piece for gluing? seems that if I make a mistake I'm screwed.
I'd suggest you to carefully inspect the IO/battery contact assembly block. You'll see where does the plastic cut might fit. I slightly rounded the corners of the ones I used as an aid for final alignment. The part of the IO/battery block that touches the case will surely guide you. And you will also see that the plastic tabs are the best references so to know the upper and lower limits of the plastic cut.
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Maybe I can install the IO assembly while the glue is still wet? But I'll have to be very careful that no glue is seeping out the edges.
I remember using a non-permanent, easily removable glue - like white, paper glue - to test the alignment so I could precisely mark where to permanently glue it later.
I am confident that based on your questions you will surely find a way to do it. And believe me, our way is usually the way we'll never forget. Try some non-permanent experiments, like the white, paper glue, and you'll find your own, safe way to go ahead. I like to experiment myself, as you can see here, so I support experimenting as well. I am also a teacher...
I am totally sorry for not to remember which chemical compound is required in the plastic welding. I never found it here, I tried the one used in acrylic molding and it has given me some good results. I'll check which component is the main one in this case, but I know it does not work in some types of plastic, must test first.
Success!
Luiz (Brazil)
Edited: 16 July 2012, 5:31 p.m.