Introduction: Fix Broken Discraft Ultra-Star Frisbee/Disc

Picture of Fix Broken Discraft Ultra-Star Frisbee/Disc

Do you have any cracked Discraft Ultra-Star lying under your bed because its broken?
Well brush off that dust bunnies and give your dying Frisbee/Disc a second life!

I just want to share this 'ible to my fellow Ultimate players and Frisbee/Disc owners who keep on cracking their Frisbee's/Discs for unknown reasons and are about to throw em away. and another reason for doing this is because of the price of this is too damn high! I live in the Philippines and the city I live in does not sell this kind of brand. So i need to order online add on shipping and etc etc..(I'm a thrifty person by the way)

so here it is. the 'ible hope you share this to your fellow mates! Mabuhay!

(note: repaired disc are only used for drills and exercises and not in the real game)
(note 2: sorry for low quality pictures)

Step 1: Tools

Picture of Tools

These are the tools used to fix your Frisbee/Disc

1. Modified soldering Iron (or anything that can melt plastic and make a hole (e.g paperclip + fire = hotrod)
2. Forceps
3. Blade/Swiss Knife
4. Marker
5. Blunt head pliers or Scissors (i used blunt head pliers because i had a hard time cutting the nylon/fishing line with ordinary scissors)
6. Nylon/Fishing line (not too thick or too thin, and the resistance must be high

Step 2: Find a Cracked Frisbee/Disc

Picture of Find a Cracked Frisbee/Disc

i found this Frisbee/Discs along with the other broken ones under my bed

Clean it with soap and water, clean the cracks also while your at it.

Step 3: Make Your Mark

Picture of Make Your Mark

Make your marks straight and clear. its to your preference on how near or far the holes are. explore!

Step 4: Heat and Hole

Picture of Heat and Hole

Heat your Iron ( or paperclip ) and make a hole where you place your mark.

hold the iron straight and no sudden movements, it might cause more damage.

Step 5: Scrape

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Scrape off the excess molten plastic.

Step 6: Stitching

Picture of Stitching

grab your nylon/fishing line and cut a length to your desire.

in stitching the Frisbee/Disc you could use the given pattern i have attached for your convenience.

Step 7: Now Comes the Fun Part. Tightening the Strings

Picture of Now Comes the Fun Part. Tightening the Strings

So your done with the stitching eh?

now we are here to tighten the string, grab your forceps and try to tighten the strings by pulling each section one by one until the end. repeat until there are minimal or no movement/friction on the cracks. to make life more easy, pull the last piece of string while tightening the sections so you can tighten it even more and more and eliminating friction and movement. i might be difficult at first but you'll just get a hang off it.

Step 8: Knotting

Picture of Knotting

knot the end of the string making sure that its really sturdy, secure and wont slip off. cut the excess string. and you are done!

Step 9: End

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I have repaired numerous Frisbees/Discs and use it for drills and practices , these are the disc that i repaired for our team, we are currently saving for to buy a brand new Frisbee.

regarding to the "aerodynamics","weight" and others.

they still can fly straight like the real thing
the weight is still the same
they hold up for a quite a long time (or until a new crack has appeared)

so this is the end of my tutorial. comment and share.

this is my first 'Ible by the way. please be kind in the comments section and sorry for some wrong grammars


comic geek (author)2014-01-26

Wow! After doing this, my disc flies. It does wobble but beggars can't be choosers!

JM1999 (author)2014-09-17

Does the extra weight affect the flight?

I have a cracked yoyo diabolo and I tried gluing it and the weight offset it.

LesB (author)2014-01-12

Of course one would like to be able to just glue broken stuff together, but plastics are resistant to gluing, and the Polypropylene that the frizzes are made from is probably one of the harder plastics to bond. Hence your clever repair method.

I tried googling on adhesives for Polypropylene and found one site that rated JB Weld PlasticWeld as an adhesive that adheres most plastics "almost perfectly". If I were out to fix frisbees, I would give this a try. It might work well alone, or in combination with your method. I'm getting some of this stuff anyway, just for general plastic bonding.

zandermar18 (author)LesB2014-01-16

I have tried the JB Weld on Frisbees and it holds, but when the Frisbee hits something, the epoxy breaks.

dimtick (author)2014-01-09

Have you tried heat welding the plastic? the heating iron that you use to drill the holes can also can be used to weld the plastic. it's a pretty simple process for small projects. Just heat up the edges with the heating iron and fuse the edges back together.
to be honest i've never done anything like a frisbee that takes a lot of abuse so I don't know if the weld is strong enough but it may be worth experimenting with.
from a quick search I found this:

Nice instructable by the way

wardog (author)dimtick2014-01-09

i tried it. but it still opens up. we might say... weld the plastic together and then stitch em.

LynxSys (author)wardog2014-01-12

I used to fix kayaks, and plastic welding only really works for
linear plastics (i.e. plastics that are not cross-linked). If the weld
failed, it either wasn't hot and well-mixed enough, or the material was a
cross-linked plastic. Also, don't forget to drill out the end of a
crack, even if it's going to be welded.

To return to their
original strength, cross-linked plastics usually have to be fixed by
mechanical means (typically by bonding a patch across the damage). I found
an excellent explanation of
using G/flex epoxy (from West System) to fix cross-linked plastic items

Hopefully this will be helpful to someone!

dimtick (author)LynxSys2014-01-14

ok....I have no idea what cross linked plastic is, but since it's part of a kayak i'm guessing that it's stronger than regular palstic. :)

I read your article about the kayak. I'm really interested to know how well your patch holds up over time, not just the abuse on the water but also being subjected to winter freeze thaw cycle.

the plastic welding that i've done has been on purely decorative items that don't take any abuse (other than my kids dropping them).

i did a quick google search and found this article which recommends using plastidip which is the rubber coating you put on tool handles. this is something that I've never tried and never even heard of until now but i thought it was worth throwing out there.

LynxSys (author)dimtick2014-01-14

Cross-linked means that the polymer chains that make up the plastic object are linked to each other; so the plastic is stronger on a molecular level. When something made of cross-linked plastic is cracked, those additional bonds are destroyed and that strength can't be restored by just melting the plastic back together.

In terms of the uses of the two types of plastics, cross-linked plastics (like ABS) are able to be used in thinner applications because they are stronger and stiffer, while linear plastics need additional thickness for strength and are often more flexible (which can also mean that they are more durable under many conditions).

One clarification, the website that I linked to isn't mine. I've done many similar repairs, but I can't take credit for that specific one!

As to PlastiDip, I use it on tool handles fairly often and it's great stuff, but it has no adhesive properties. I'm not sure why someone would recommend it for filling a crack in plastic.

korlich (author)2014-01-13

How's the balance when thrown?

wardog (author)korlich2014-01-14

its unnoticeable so far. but sometimes they flop a little. ( might be because of [A. loose tension or B. weight of the nylon string] i will still run more test with this ) i might post a video about how it performs.

aebe (author)2014-01-14

Hello . You can get hot glue gun sticks for repairing plastic , auto parts store or go online for a source . They are meant to be used with a plastic welder , but a hot glue gun and a soldering iron will work . I like the idea of stitching the crack , would make it much easier to keep things lined up .

Ricardo Furioso (author)2014-01-13

Great, clear, and useful. Thank you so much for sharing.

NitroRustlerDriver (author)2014-01-13

If you drill a small hole at the end of the crack/tear (where it starts, not at the edge), it will prevent the crack from spreading further. Like this:

msemtd (author)2014-01-13

I very much like this instructable (well done wardog !) -- it is good to know that this method of frisbee repair is tried and tested by your team.

OhWheelie (author)2014-01-12

You have your soldering iron out, couldn't you just weld the seam up with it?

lbrewer42 (author)2014-01-12

Great fix - excellent idea.

one small tip...

ask any experienced fisherman... either finger nail cutters or toe nail cutters are an essential part of a tackle box for cutting fishing line - makes very easy work of it.

ivanbakas (author)2014-01-12

Great job!

A method that worked very well for me, is to use unwaxed dental floss and when done stitching, add a drop of thin cyanoacrylate glue on every stitch.

Easier to make tight stitches than fishing line and lower profile!

dgateley (author)2014-01-12

Cool, but you omitted the most important hole of all. Make one at the very end of the crack to prevent it from growing (which it can do even after it is stitched.) This should be done any time a crack appears in anything. Originally used in airplane maintenance.

askjerry (author)dgateley2014-01-12

I agree. A tiny hole at the end of the crack will eliminate the stresses there and stop if from expanding further. I learned about that when doing a small repair in an F4 aircraft a few of decades ago. (Dang that makes me feel old.) Anyway... yeah... it works.

RedRock (author)2014-01-09

Well done! Good job of 'making do' & using what's at hand, so that some extra life is squeezed out of items that would usually be thrown away. I was also going to suggest using your solder iron to do some plastic welding - but together with some stitches - as the weld on its own will most probably 'burst' open if ķnočked in the right spot. A tip that Ive found helps with the plastic welding is to heat both pieces that you intend joing and then still try and blend the one into the other, sometimes you may need extra 'plastic' & the best is to use the same or similar type so don't throw away those that break again - 'harvest' the extra plastic from them.

wardog (author)RedRock2014-01-09

another style i did was applying super glue to the strings and cracks for added security.

RedRock (author)wardog2014-01-09

Next time use Bicarbonate of Soda powder with the super glue. The two create a join that can be sanded down nice & smooth. If you combine powder colouring with the Bicarb you could even try to get close to the colour of the plastic.

sabr686 (author)RedRock2014-01-12

Using super glue and another substance as a congealer will make a great bond; just be careful here, because it makes a very hard, stiff seal. If you expose it to very cold temperatures and give it a good thump, you could shatter the weld. But, it it, after all, a used frisbee! I suggest using very fine ground bone instead of baking soda in order to avoid potential powdery welds.

seamster (author)2014-01-09

Very nice! This is a great way to get more life out of your discs.

Can I add one more tip? If you drill a small hole (or melt one) right at the point where the crack ends, it will stop the crack from spreading further inward.

wardog (author)seamster2014-01-09

yes i did that also. it was not clear from the angle a shot from :)

CHaD4HiM (author)2014-01-09

Great job! What kind of team are you on?

0bes (author)2014-01-09

Nice. I should have done this to a couple discs back when the team destroys them.

I end up buying my discs from here -

They'll often sell defective disc (no physical defects, but graphical) for next to nothing.

joey56 (author)2014-01-09


Kiteman (author)2014-01-09

That's cool. Even when shipping costs are not a problem, these are expensive discs to replace!

(I assume you put the knot on the underside of the disc, so it doesn't catch your skin?)

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