I got a Power Mac G5, the basic 2004 model, with 1.8GHz single CPU and RAM expanded to 2GB, two 80GB drives. Bought on a flea market, with intent to restore, fix and maybe trade for some other computer I don't have.
So, first tests shown that the machine is technically 100% working. However, its casing does not look well.
1. There are numerous scratches on it. Contrary to previous Macs which could be fixed with specific chemicals, this one has no polymer/plastic coating at all and removing these scratches seems to be impossible. I think that the surface of this smooth but crisp aluminum has been made by shot peening and then anodizing - process impossible to reproduce at home. And I was thinking that it was just brushing
.
2. The handles are partially broken off the casing - on the door side, in front-bottom and rear-top. I've seen lots of these damages while looking for G5 to my collection and I was curious how they occur. So having a Mac with this damage I did a quick, simplified FEA of it
(the best way to waste a few hours and not mine 64-core HPC workstation). Summing up - if a specific vertical stress on handles is exceeded, the handles will slide aside, acting like lever, pulling its ends (part with door) apart from chassis. The parts for screws have extremely small contact area (are they made using friction welding-like technique but with thread?) and they break off starting from handle. Analysis conclusion: Do not sit on your Power Mac G5 or Mac Pro in aluminum tower casing.
I did two different repairs of these. Generally, it's important to remove all remains of broken mounting points. I have no idea how they put these bolts in, because to remove them you need some magic screwdriver which acts in direction opposite to being lead in (read: bent 180 degrees and still rotating) but it was possible to remove bolts by rotating them very slowly using pliers. Then removing broken remains of mounting points was easier. This is important as they like to rotate in their holes and make the cover not touch the chassis.
For the bottom part, I drilled a hole in part closest to handle and, using a hole from existing mounting screw on chassis, just used a screw, nut and washer. If the drilled hole has a nicely finished edges the screw's head is flat with casing. This looks relatively nice however the screwdriver hole is visible.
For the top part I tried with "Aluminum glue" - applied yesterday, today it still does not catch. I feel that it'll end with scratching this glue out and using the previous method.
P.S. I should put such notes on some blog... they may be useful in future.
EDIT, 2018-07-04, 00:28 - I was right. Spent last 3 hours scratching glue out and drilling hole.