Today my son broke his Buzz Lightyear's arm at the elbow joint. Now I'm not sure if all the joints are similar, but I suspect that they are, and could very likely be fixed the same way should they break.
Regardless, we have a toy with a broken limb, which means it's not being played with, and as we all know a happy toy is one that is being played with. So let's get to work!
Step 1: Preprare for Surgery
The screw that is located in the shoulder is easiest removed if you rotate the shoulder joint so that the screw is facing downward into what would be the armpit.
Step 2: Remove Elbow Joint
Once you have the elbow joint removed, open up the forearm and remove the small gray plastic piece that is contained within. Set aside the forearm pieces,and the hand. We're going to focus on the small gray piece that you just removed and the elbow joint.
Step 3: Reassemble the Elbow
Align your two pieces so that the break on both pieces fit back together like a puzzle, and thread your screw back in. Make it nice and snug, but don't over tighten or you will strip the plastic and have to use a larger size screw.
I suggest using super glue on the screw threads when you're ready to screw the two pieces together, just for a little extra rigidity. I didn't do this, and shortly after my son was playing with buzz his arm started to be able to rotate slightly(the wrong way), but still holds in place.
Step 4: Finish Up
Once you have the notches cut out, remove the elbow joint from the forearm, and assemble it back into the upper arm piece. Do this first, as it will be easier to put the forearm back on without stressing the repair than it would if you had the forearm already on and acting as a fulcrum when you were to reinstall the joint.
Now that you have the elbow joint reassembled just put buzz back together in the reverse order.
Step 5: Done!
As of my writing this 'ible it has come to my attention that the arm while still holding strong has the ability to shift a little perpendicular to the joint axis. Which brings me back to my previous comment about using super glue. When my son falls asleep later, I will remedy this.