Fixing a Crack in Plastic Laptop Case Near the Hinge

Usually there is no problem fixing plastic cracks with some sort of glue, but this particular crack is very close to the hinge. As you can see, it was once glued with nearly no effect. Every time you open or close the lid it is being torn apart. As a result, the hinge experiences deformations, so it's going to be badly damaged if the crack is not fixed.

Instead of just gluing it again I will apply a technique which is used for car bumper repair.

Of course you could do the following procedure with the inner part of the case. However this particular laptop had other issues to be fixed, so it was easier to do it this way.

You'll need an old soldering iron, some pliers or a similar tool, insulation tape, two-component epoxy welding glue (could be found in a car parts store) and a handful of regular small nails.

With pliers or other tools, bend the nails to form L-shaped brackets. I also recommend that you slightly cut the nail heads so that they will not stick out at step 3. Do not remove them completely. They will be needed to ensure a durable connection.

Usually it's not a good idea to melt plastic with a soldering iron, so I suggest that you use some old and not powerful one. The temperature should be just enough to melt the plastic case. You could also install the tip upside down to protect it from dirtiness. Flat tip is also more convenient for this purpose.

Put a nail perpendicular to the crack and heat it with a soldering iron until it sinks to the level of surface. Install another one in the opposite direction and so on.

Make sure everything is ready before preparing the glue. Once mixed, it usually gives you about five minutes to get everything done. Cover the crack surface with glue and leave it for several hours.

⚠️Please read carefully the instructions for your particular glue before starting this step.

Stick some pieces of isolation tape around the bump and use sandpaper to even it. However you'll need to leave a thin layer to ensure reliable connection. Maybe 0.5–1.0 mm or so.

You could paint the surface if you wish or apply a sticker to mask the bump.