Start by using pipe cutters and cutting around the middle of the tank or so. I drew a line so I could match the pieces up later, but you don't have to. Make sure you give the tank a good sanding before you draw the line. I can't remember because I did all the steps besides putting it back together maybe a year or so ago, but I think I got bored with pipe cutters and just hacksawed it open. If you use a saw, DON'T GO THROUGH THE MIDDLE! Go around the whole tank rather slowly so you don't start cutting and messing up the spring or the pin.
Once it's open, it's pretty obvious what must be fixed.
Yeah, that little arm thing on the rubber stopper snaps often on these old blasters unfortunately. Take the pieces and super glue them back together, add extra glue as desired to strengthen the joints. Alternatively you could look into filling stopper with putty and then drilling and tapping for a eyelet screw. I believe Jlego has done this.
Alrighty, now that you have given that piece you fixed a good 24 hours to get a full cure, it's time to put this thing back together. Sand the ridges on the inside of the tank and sand the outside (if you haven't already sanded the outside.) Slap some superglue on ONE side of the tank, make sure to goop it all over the edges but DO NOT get any on the rod because it will drip down and ruin the rear seal. Let this get a little gel like by waiting a couple seconds, then push on the other side. Twist the other side while you do this to ensure that the plastic bonds well, and also to ensure that you are aligning everything. I just eyeballed it and it came out fine. Since I used a hacksaw and just randomly put the halves together I had some pretty obvious little holes, but this is not a problem! Just glob a little super glue all over the seam of the cut, and start spreading it around. Stick on the end of a piece of electrical tape firmly and tightly wrap the tank with a wrap, spreading the glue around as you wrap to make sure the electrical tape is bonding well. Wait 24 hours, and you're done!
This does not weaken the tank as far as I know, I took it to 4 pumps on a plugged 2k pump and it held fine. You can use this electrical tape technique to repair and reinforce all sorts of things too; I broke a lawn sprinkler on accident once and I just followed these steps to put the two pieces back together and it's fine. I've also used this technique to re-attach an xbow grip back onto the body after it was amputated, and to repair cracked plastic in shells.
Well, just thought I'd share this little project. Suggestions, comments, questions, whatever?
Edited by Blue, 27 October 2011 - 07:00 PM.