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This DeWalt DW911 jobsite radio was out by the trash bins on bulk pick-up day in my folks’ wealthy Austin suburb a couple months back. It’s got a nice AM/FM stereo receiver with an AUX input, decent speakers, and a port in the back to charge a DeWalt or DeWalt-compatible tool battery pack. If it’s not plugged into the wall, it can run off the battery pack instead of charging it. All that, plus DeWalt yellow. For which I am a complete sucker.

Anyway. Somebody threw it out, and I grabbed it. These cost like $100, new, and I’ve been eyeing them in the big orange store for years but could never really justify the expense. Unsurprisingly, this one didn’t work at all when I plugged it in. Getting the case open was a bit of a trick; it turned out to be glued shut along the seam. I took all the obvious screws out and would’ve wasted a lot more time and done a lot more damage looking for the “hidden” screws if some thoughtful soul hadn’t figured out the glue thing and taken the time to buy provigil online india. Thanks, man! A few strategic whacks with a rubber mallet opened it right up.

Anyway, once I got it open, it turned out to be a fuse. I love it when that happens. And I even had the right spare on hand in my parts box. Happy.

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This method gives good results with simple hand tools:

  1. The original part is affixed to a piece of blank stock of appropriate thickness. Double-sided “carpet tape” is very useful for this purpose. Excess tape can be trimmed away with a hobby knife.
  2. Any round holes in the original part are drilled through the blank with a hand drill, using the original as a guide/template.
  3. Close-fitting bolts are passed through these holes and fitted with nuts and or washers to clamp the original and the blank in close alignment.
  4. A hacksaw, a hand nibbler, and/or a file are used to trim the stock down to the original part profile on all sides. For hacksawing, it can be useful to secure the stacked blank and original part to a piece of scrap wood.

Shown here are two admittedly rather boring examples: A replacement hasp for my outside breaker box in stainless steel, and a duplicate strike-plate for a lockset on my rental property door. Both parts have performed flawlessly as replacements.