How to repair a loose or broken Zoomer flip-cover

Has the hinge mechanism on the flip-cover of your Zoomer worn to the point where the flip-cover falls off in your hand? If so, it's probably due to two small plastic nubs on the flip-cover which form part of the hinge (and, IMHO, are the weakest point in the otherwise sturdy design of the Zoomer). Those little nubs wear down with use, and eventually they don't hold the flip-cover to the hinge on the main body.

I've fixed two Zoomers with this problem, and documented the process when I fixed one recently. But first, a...

Disclaimer: This process appears to work just fine, but you're solely responsible for whatever might result from following my advice. It's very possible to damage the Zoomer case during the process, and although I don't anticipate any problems, it is also possible that following this process will introduce new problems as the new hinge mechanism becomes worn.

With that said, here goes:

Tools that you'll need

• A Zoomer with a broken or loose flip-cover
• One "jumbo" paper clip (these are 1-3/4" when coiled) or similar diameter stiff wire
• A small drill bit, sized to fit the wire
• A small drill, hand operated or low power
• Two pairs of pliers, preferrably needle-nosed
• One pair of diagonal wire cutters, suitable for cleanly cutting the paper clip
• One dental pick or similar tool (see use, below)
• One x-acto blade or similarly sharp razor edge

Step 1: Prepare the flip-cover

Using the dental pick, remove the soft rubber plugs on each side of the flip-cover near the hinge points (see photo, below), exposing a small cavity (now you know why I recommend a dental pick :-).

Using the x-acto blade, shave off the nubs on the flip-cover, or what might be left of them (see photo, below). You'll want to shave them off completely flat.

Use the tip of the x-acto blade to carve a small indentation in the plastic, creating a guide for drilling. The indentation should be centered where the nub used to be.

Step 2: Drill holes where the nubs used to be

A few cautions about this critical step:

• Do your best to drill straight, even though the opposite side of the flip-cover will likely get in the way of your drill motor.

• Be very careful not to drill past the cavity and through the outside edge of the flip-cover.

• Most importantly, be careful not to allow your drill to remove too much plastic surrounding the hole. This is the new weak point in the hinge, so leave as much plastic as you can.

Step 3: Drill out the holes where the nubs used to fit

Step 4: Insert a wire through the holes

Thread the wire through the flip-cover cavity, through the hole you drilled in the flip-cover, through the hole you drilled out in the main body hinge, and into (but not through) the opposite hole in the main body hinge (see photo, below). Since you'll need to slightly bend the wire as it threads through the flip-cover cavity, you may find helpful to rotate the wire as you thread it. Be gentle and don't force the wire.

Step 5: Trim the excess wire and complete the insertion

Using the dental pick, needle-nose pliers, or whatever works for you, gently push the cut end of the wire so that the other end of the wire threads through the rest of the main body hinge hole, the opposite-side flip-cover hole, and into the opposite-side cavity. The cut end of the wire should now slip into the near-side cavity.

You're done!

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