Field Repair for a Shattered CS Arm

[Wallace]

Request for Information on "Putting a Cast on a broken Right ARM " on my Control Shaft.When my control shaft Height Adjusting Collar began to bind with "Green Plastic Shavings " clogging up the internal threads, I was sent a replacement CS under warranty.

HOWEVER- the shipping container on the first NEW CS box - was crushed in on one corner and the New CS had the Right Arm almost completely severed with a crack running from the lower, rear of the "tube insertion" socket on the column upwards and to the right of the attachment bolt under the grey plastic lens cover and key port surround. That plastic part was found loose in the shipping material.

The crack runs between the bolt and the "Blinky" LED display, on over the front and disappears into/behind/under the undamaged, front plastic trim with the adhesive SEGWAY "bumper."

Anyhow, SEGWAY sent me another NEW CS by a different carrier and told me to keep the "second CS which had been trashed out." I had sent them a dozen digital photos to document the damage for insurance purposes. Since I do not know how to attach a photo to this message, anyone wanting more graphic details will have to e-mail me directly for the grizzly details.

My Question is - Because I am unable to remove/unsnap/unscrew the decorative, front cap piece - it must be "potted or bonded" with some industrial adhesive on the ends only where the metal handle bar grip shafts go into the upper and lower, ultrasonic welded, rear halves - WHAT DOES IT LOOK LIKE INSIDE?

I have "engineered" a reinforced fiberglas exo-skeleton cast for a "Lobster Claw" so I will have a spare CS which should be stronger than a New One.

I am just curious as to what the handlebar assembly has in it besides wires, the Hall effect truning sensors, the Blinky LED and the Keyport connections?

Has anyone discovered a non-completely destructive way to "Un-glue" the front cap without rendering it no longer asthetically appropriate?

How do you remove the front trim piece? When I flex the handlebar halves I can get the crack to open and close because only the upper rear and lower rear plastic members which carry the metal rods for the grips and the center, metal attachment mechanism with the bolt through it are the parts affected by the "Lobster Claw" fracture.

No matter how I pry or twist, I cannot get either end of the FRONT Trim piece to let go. It must be adhesive bonded at the outer extreme ends. I can see some plastic tabs along the trailing edge which locate this piece with the other two, but, I cannot get the whole thing apart. Suggestions?

Tripod and ROVER


Tripod and ROVER

[sholloway]

I just took one off the other day. I too thought it was glued but when I called Segway to ask them how to remove it, it worked. Face the machine, push UP on the bottom of that trim piece with your thumbs, this will cause it to rise at most 1/4 of an inch. Now "grab" the top of the piece that has risen above the handlebar with your fingers and pull towards you. There are several places that are connected with a wedge type shape but you should be able to pull them all out from the top down. After you get the top loose, you can easily pull the whole thing off.
Maybe your's is glued but I would have sworn that mine was too until I did this and it came right off. The replacement just "pops" right on with a smack of the hand.

[Wallace]

Thanks, Scott for the advice. It took a bit more than thumbs to do the job, but, I got the front cap off. There was a lot more damage in there than I thought at first.

The whole right arm was broken all the way around. The wires and flat gray cable to the LED were the only things - well, the front cap was also still intact- that held it all together.

I think that some aircraft grade fiberglas cloth, resin and FLOX additive as a filler will do the trick.

Now that I can get inside, I will be able to plan out a strategy to save the $500.00 NEW CS.

Tripod and ROVER