Zytel handle/frame repair

[treefarmer]

Have a Gerber 450 EZ OUT USA knife. Several years ago the zytel frame/handle under the rubber inserts cracked and broke in several places. What material will bond with the zytel? My epoxy instructions says it will not work on nylon and I believe zytel is some sort of nylon. This knife is just an easy carry because it is so light and I'd like to use it now and then. Any thoughts on how to patch it up? Treefarmer

[knife7knut]

What type of epoxy are you using? I would try using JB Weld as that stuff will bond to just about anything except maybe polypropylene(NOTHING bonds to that stuff).
I don't know how much room you have to work with or how accessible the area to be reapired is but I would try this:

Drilling a series of small holes(not necessarily completely through) on either side of the crack and fitting a piece of thin sheet brass over the area before applying the JB Weld.This will provide some additional surface area for the material to adhere. I tried this recently when repairing some aluminum hinge levers in a vintage tackle box with fold out compartments.Welding wasn't an option and manufacturing new levers would have entailed taking several hinges apart and then trying to find new rivets to install.So far the repair has worked fine.

[treefarmer]

Thanks knife7knutfor the response. JB Weld might just work. I've got Loctite general purpose epoxy. The problem with this knife is the zytel frame is molded in such a way that the rubbber inserts would be almost flush with the side of the handle, leaving a very thin, 1/16th"of backing for the rubber insert to be attached to. These thin pieces have cracked and broken with use and by removing the rubber I will build up the handle and reshape it to match the original lines. It's just a shame to have to park a knife that you like to use if it can be patched up. I have no sentimental attachment to this knife, so any repair just prolongs its' life. Treefarmer

[Big Barn]

can you post a picture of the broken area that you are talking about ?

[treefarmer]

Big Barn, Here's a couple of pictures of the broken areas. I'm going to try to build up the areas on each side where the rubber inserts have broken loose and discard the rubber pieces. As knife7knut suggested, there is enough material to drill a series of small holes to allow the JBWeld to make a tight bond to the zytel. May work and it may not. Treefarmer

[muskrat man]

is seding it ack to gerber for a replacement out of the question?

[treefarmer]

muskrat man, I acquired this used knife some years ago from an individual and had not thought about dealing with Gerber about the problem. Had I bought it new, I would probably do that, but under the circumstances I wouldn't feel right with that approach. By the way, I haven't forgotten about the draft horse bone, the fields on that farm had been plowed before we got about 10" of rain in a 2 weeks time and it's been a little boggy for the pickup truck. Treefarmer

[orvet]

I have told Gerbor that I bought a used knife that was broken when I got it and they still replaced/repaired it at no charge.
Pretty nice folks to deal with.

[oldgoat1911]

Sorry if I am stealing your question but I personally like the EZ Outs and have wondered what steel was used because it works pretty good. ..Thanks....Herb

[treefarmer]

oldgoat1911, my limited knowledge of this Gerber comes from reading on the internet. 450 is the ID of the stainless used in the blade. Comments I have read say it is a rather brittle steel, folks wrote about dropping the knife and breaking the tip, etc... I got this one used and enjoy it as a light weight that I don't mind buggerin' up and resharpening as needed. The EZ OUTs seem to be rather easy to locate and aren't expensive, but I'm going to attempt to repair the zytel handle just to restore the width of the handle/frame to be comfortable to use once again. Treefarmer

[treefarmer]

Here's a picture of my attempt to repair my Gerber EZ OUT's handles. Found that JB Weld will not adhere to rubber, so I put a piece of an old innertube on each inside surface of the zytel frame and closed the blade. This created a form for the JB Weld to bond with the zytel and keep it in the original position of the broken/cracked rubber inserts and keep it off the blade. Did one side at a time, after it cured I removed the rubber strips and then shaped it to match the contour of the handle. So far so good, at least it will be comfortable in the hand when I decide to use it. Treefarmer