CPS 1500 1700 pump repair

[soakinader]

Materials:

-Drill bit set (The more the better)
-*3/8" bit
-*1/4" bit
-Glue (Acryllic super glue or epoxy)
-Piece of plastic pipe/rod close to 3/8" OD, 1 inch or more in length
-The complete, original pump

Fixing a broken pump

So what I did was take a piece of ~3/8 OD hollow plastic rod, and jammed it into the pump. You can either sand down the plastic rod or take a drill to the interior of the pump, or both. Drilling the pump is a good idea- it's broken anyways, and it will mean more material for the strength of the inner rod. When it just fits smoothly, it is time for the glue. If you are using epoxy make sure it's a bit looser so that there is room for the epoxy to spread. Push the rod in quickly and get it into place before it gets stuck.

Do one end at a time, making sure to maximize the surface area for the glue. Hold the shaft straight and let the glue set for several hours.

Then carefully drill a series of small holes in the plastic rod, in the center of the old hole until you get up to 1/4". This should fit smoothly inside of the pump handle. I tried 7/32 but it was too tight and broke the inner rod the first time. So go for 1/4".

You can see the rod inside the pump.
And done. The pump is now fixed. It's been used quite roughly and so far so good. You could also do this proactively to reinforce the pump, just make sure you have a hammer handy to put the rod in all the way. Drill a hole in the rod and you are done. Now if only you could buy strong plastic rods from somewhere. The piece I used was from some broken gardening framing thing.
*EDIT* You can use a piece from a plastic coat hanger. Just cut it to size with an exacto knife/sand it.

[HBWW]

An interesting and unique approach, one requiring fewer materials. However, durability seems to be a potential concern, though I wouldn't know for sure having never done a repair this way myself.

[soakinader]

I think the durability is good here, it's like a proper tape weld on a steel tube frame. The rod I used is very tough, and it bonds to a large surface area which is parallel to the direction of force, and held by friction on the inside surface of a cylinder.
How else would you repair a pump?

[SEAL]

I did this to my 1500 and it lasted for a few pumps. Granted, I used a wooden dowel instead, but it was the plastic parts of the original pump shaft that broke apart again; the handle is still attached to the dowel. I'm going to try slathering it in epoxy and put it back in.

[marauder]

I have never seen a pump snap where the pump handle attaches. Has anyone else seen this? I've seen a lot of breaks in the middle. Those are incredibly easy to fix. This, while not quite as easy, still looks like one of the simplest repairs out there. I've never had a repaired pump break a second time.

[soakinader]

I've had this repaired pump break about three times because I was relying on the strength of either glue alone, or once with a crappy plastic rod from a toy. This final time used a very strong piece of plastic that fits very well. It is practically a tape weld.
*EDIT* I would highly recommend for someone to replicate this repair, that they should use a plastic coat hanger! With a little bit of shaving, it works great for this delicate repair.

*EDIT* After two years of use (and some abuse) this pump is still holding up strong.