Last Sunday I went again to the flea market and I got something interesting: A 256kB XT mainboard in original package. The problem has been quickly found and bad chip has been replaced, so now I have a 4.77MHz mainboard in a good condition.
Two weeks ago: Two Compaq Aero notebooks, 33MHz 486. With hard disks, 4MB of RAM, batteries, complete. The problem was that one had trackball not working (fixed by seating the ribbon cable) and the other one had broken hinge (not my photos of the exact same problem:
here).
The hinge was a problem. If it is broken for too long, it will destroy casing. There are no such hinges for sale, and it looks like that another one would break too as its arm is made of cheap Zinc-Aluminum alloy. I decided to make a new part using old metal plate from some PoS keyboard I took from recycling some time ago and desoldered for microswitches.
I do more complex metalworking at workshop in my workplace, where I have access to a better tools. So I asked my friend for the workshop key to repair the laptop. And of course do they still have a table drill here? Circular saw? Vice and hammer? Yes, that's great. I took a key, and additionally 2.5mm drill and quite large hammer and went to the workshop.
My friend shares a room with some researcher. His face when he finally understood that I really want to repair the laptop with such tools was... quite unusual, he recently heard that I repaired an expensive server there
.
OK, the idea was simple. First, removing the broken part, leaving only the hinge and shaft. To do this, it is needed to hold the broken part in vice, put a nail or screw in the hole and gently hit it until the hinge falls off.
Then, I cut an L-shaped piece of metal from the keyboard plate and machined it with file to dimensions. It had square holes for keys, so it was easier to cut using existing holes. The shorter part of "L" is a bit wider and longer, so it was possible to grab it into vice and just use the hammer to make a round profile, with internal diameter like the shaft protruding from the hinge.
The next step was to push the hinge's shaft into it by squeezing it in vice. Generally the harder it goes, the better.
Finally, drilled holes in a longer part of "L" and put it in case as it originally was. Although this is ready to be installed, there are two things I recommend:
1. Find a longer screw for the part closer to the keyboard (it breaks there). Because my re-make was thicker and because point 2.
2. Use a washer between this screw's head and the metal part.
There is literally no sign outside that the hinge is re-made.
Now I have 3 of these, fully working... and no floppy drive.