Repair eye glasses with a broken bridge (flexon sunglasses)

I bought a pair of Nike sunglasses with flexon frames a few years back. They were the only pair in the whole shop that would fit around my gargantuan head. I used to crumple up my sunglasses in an impossible shape just to amaze my friends when they bounced back. That finally came back to bite me when the bridge snapped and I suddenly had two pairs of sunglasses for one-eyed pirates. The flexon alloy doesn't lend itself to being soldered directly and there just isn't enough material to tape (not that I would where them in public like that, but I did try). I needed a tube made of a metal that bonded well with lead and tin that I could insert both sides of the bridge into and solder. D&J Hobby on Saratoga Ave in San Jose had just the right tubing from K&S Engineering. For this project, you will need:

- Small pliers
- sandpaper
- a saw, small tube cutter or abrasive cutoff tool to cut the tubing
- Soldering iron
- rosin core solder
- Acid Brush and Alcohol to clean the rosin after the repair
- A dab of clear finger nail polish
- 0.25 - 0.5 inches copper tubing with an inside diameter slightly larger than the outside diameter of your bridge. Square tubing is available if the bridge you are repairing isn't round. ( http://www.djhobby.com/ (retail) or http://www.ksmetals.com/ (wholesale))

Step 1 Assess the situation

You have a pair of eyeglasses that has a broken bridge. My pair had a bridge made of flexon. It not perfectly round, about 1.6mm x 1.3mm. You will have to select a tubing that has a slightly larger inside diameter to make the repair. The tubing I found was only spec'ed with an outside diameter and a wall thickness. It turned out to have a 1.7mm ID. I aligned the two pieces at the break and saw that the bridge was curved. My first attempt at a repair splint followed this curve. It turned out to be too difficult to bend the small tubing precisely enough without jewelers pliers which I don't have. When I dry fitted the splint I could never get the two halves of the glasses to align correctly. I scrapped the curved splint and went with a much shorter straight one.

Comments

[SharpyWarpy]

I want to thank you very much for submitting this instructable. I used it to fix my flexicon frames and it works great. I noticed I could not solder directly to the flexicon material some time ago when my frames first broke. I had tried to solder a small piece of copper wire to the back side of the break. When I saw the solder would not bond to whatever type of alloy flexicon is I tried epoxy. Alas, that didn't hold very long at all. But this guide is the answer. Thanks again.

[lou_p]

I had a similar issue and went directly with the shrink tube. Worked fine, looked great, but had rotational issues. Lou

[Gthing 2.0]

wow u must b a psych my glass just broke OH by the way great instructables