How to Repair Broken Plastic Parts (Broken Bottle Cap)

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About: -----------------------------------------------------------------16 year old, sick with a deadly disease called DIY-itis!-----------------------------------------------------------------Hi FTC! My I'bles con...

Part of the reason for why I haven't made an Instructable for so long is because I've been working on a REALLY big project right now.

The other part is trying to find out how my water bottle found out about the upcoming Fix-it! contest, and decided to break. I came up with a fairly simple way for repairing it, so in this Instructable, I'll show you how it was done.

To do this, you'll need a Hot Glue gun, some galvanized steel wire, a drill with a small drill-bit, a file, and wire cutters. Needle-nose pliers might also help.

Let's get started!

Step 1: File!

I used a file to rougher up the surface, since this helps the hot glue adhere better. The more, the better.

Step 2: Drill!

I drilled a hole in each side of the cap. I recommend using a drill-bit that's slightly bigger than the wire that you chose

Step 3: Wrap the Wire Round the Cap

I wrapped the galvanized steel wire around the cap. I think using more thinner wire would be stronger, but this doesn't have to be very strong. I cut off the excess with wire cutters, and moved on to the next step. If the wire that you chose was really tough, you might need to use pliers...

Step 4: Hot Glue!

I poured tons of hot glue onto the cap. Add only a bit every time, and it might take the glue a few minutes to cool off, so be careful!

Step 5: You're Done. Ta-daa!

Done!

Now, If you'd like, you can shape it in with your hand (while the glue is still warm, it feels a bit like putty), cut off the excess with a knife, and give it a "polished" look with a lighter. Good luck! :)


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    20 Discussions

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    ArmzapYonatan24

    Reply 1 year ago

    i have another way even tho i never tried it.....just use surge

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    ArmzapYonatan24

    Reply 1 year ago

    not surge sorry but exopy putty

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    livichrisYonatan24

    Reply 1 year ago

    make the holes into small slots and use a zip tie.

    make the holes larger and use paracord.

    cut off the handle pieces completely flush with the top of the cap and epoxy on a new eyelet, could turn a nice piece of walnut.

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    rbclimalivichris

    Reply 1 year ago

    The walnut repair would look awesome!

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    Yonatan24rbclima

    Reply 1 year ago

    I still have another broken bottle... :)

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    Yonatan24Bones4000

    Reply 1 year ago

    I only wonder if it's dishwasher safe... :)

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    Bones4000Yonatan24

    Reply 1 year ago

    There's one way to find out. ? I don't see why it would not be. Dishwasher water doesn't get hot enough to melt that type of glue to the best of my knowledge.

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    Battlespeed

    1 year ago

    You can do jobs like this very easily with epoxy putty. This is an
    epoxy that comes in a moldable consistency. You can shape it like putty, and it hardens
    into a very solid material. There are different types (wood, plastic, metal etc), some of which
    are even used in very demanding marine applications. One like JBWeld's "PlasticWeld" (linked below) would be
    appropriate for this job. $8 for the tube - and whatever you don't use keeps for a long time. You can buy this type of product at most any hardware store.

    http://www.jbweld.com/collections/epoxy-putty-sticks/products/plasticweld-epoxy-putty

    2 replies
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    BattlespeedBattlespeed

    Reply 1 year ago

    Should add that I keep epoxy putty sticks as one of my "must-have" tools because this kind of repair comes up all the time. The other day I had to repair a plastic handle on a vacuum cleaner, and a month ago I had to create a new knob for a window fan. These epoxy putties are da bomb.

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    Yonatan24Battlespeed

    Reply 1 year ago

    I've used epoxy putty before:

    https://www.instructables.com/id/Retractable-Helpin...

    https://www.instructables.com/id/Ultimate-14-in-1-S...

    I've taken both of those projects apart, and when trying to break the epoxy putty, I noticed that it was a bit brittle, which is why I think that re-enforced hot glue is better.

    I didn't have any on hand because I think it was pretty expensive at my hardware store, and I can't stand the smell of it. Same goes with 5-minute epoxy...

    Plastic handle on a vacuum cleaner? Duck tape!
    Create a new knob for a window fan? I cave a collection of those. No collection? Use wood! :)

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    NebulaIX

    1 year ago

    I like it, it's a good idea, thought of it but wasn't sure how to go about it...

    3 replies
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    Yonatan24NebulaIX

    Reply 1 year ago

    It's even more comfortable than before!

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    NebulaIXYonatan24

    Reply 1 year ago

    lol, I guess you can go break all your other bottles, then "repair" it, or forget breaking it, just add some hot glue to every bottle in the house--- btw I voted

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    Yonatan24NebulaIX

    Reply 1 year ago

    Thanks for voting!

    I think I have another bottle that broke (different kind though) :)