The situation: I ordered a few Rebel Ground Crew figures from Tunghori a few months ago. Unfortunately, one had a defective elbow joint that immediately broke... Looked as though it had an air bubble inside the cast. Tung has always been able to supply replacement parts on previous orders, but I guess these guys sold out and he couldn't come through this time.
With most figs I'd swap the arms and use it as a custom base; however, the RGC jumpsuit has a unique sculpted texture that would make other arms look out of place. I got sufficiently bored last night to attempt a repair:
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I began by removing the broken peg from the upper arm with an X-acto, several small drill bits, and a dental pick. Next, I used a pin vise to drill into the elbow's joint disk and the replacement peg cut from a
miscast Rebel Fleet Trooper's lower arm (which Tung was able to replace; post #20155 in the link). As a precaution, I used a drill bit to rotate the disk after drilling the hole, to make sure that my reinforcing metal upholstery pin wouldn't go all the way into the disk and prevent movement. The last step was to superglue the pin into the peg and the disk. I basically rolled the dice and hoped the glue wouldn't ooze everywhere and freeze the joint. Caught a lucky break there.

Also smoothed out the RFT peg with 800 grit paper and added a dab of dielectric grease to make sure it'd spin freely and not break the glue.
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The weak spot of the repair is where the pin meets the elbow disk. The joint works, but there's no way it has the strength of a regular piece - Not much surface area for the glue to hold, and I'd imagine the metal pin would do a number on the joint disk if I fiddle with it too much. As a reminder to myself I filled one of his pegholes with bright blue paint so I know which one to baby.
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Thanks for looking!