Controller Cracked Threaded Holes!!!

dsd317 · Feb 9, 2016

I've heard of problems with DJI controllers cracking, but all four of my threaded holes that keep the controller halves securely fastened are either cracked and/or damaged beyond repair.

The only thing (aside from buying a new controller) I can think of doing is to use longer screws. The problem is that it would add more stress due to the gap from the missing pieces from the areas where it completely cracked off.

Any other suggestions?

msinger · Feb 9, 2016

Other than sending it back to DJI, you might be able to weld it back together with something like J-B Plastic Weld or Plast-aid.

Sinisalo · Feb 9, 2016

dsd317 said:
I've heard of problems with DJI controllers cracking, but all four of my threaded holes that keep the controller halves securely fastened are either cracked and/or damaged beyond repair.

The only thing (aside from buying a new controller) I can think of doing is to use longer screws. The problem is that it would add more stress due to the gap from the missing pieces from the areas where it completely cracked off.

Any other suggestions?

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If you use Plast-Aid I can guarantee you it will work to permanently fix your problem. I have used plast-aid for so many things around my house it is crazy. It bonds to the plastic chemically and physically. I got mine from Amazon, here is the Plast-Aid marketing video:

You could even use plast-aid to form new threads

Mako79 · Feb 9, 2016

Lol... Stress cracks.. I think you need the strong arm kit for the controller.
There is a batch of controllers that has RTH button (screw support) failing and it seems to be the plastic they used. Yours could be from the same batch.

Dave from Ok · Feb 9, 2016

Just get a hot glue gun from a hobby store. Put a few blobs around the edges and hold the case together until it cools. You will still be able to open it if you have to with some pressure and a butter knife. The excess is easy to remove so cosmetics are not a problem. Fixed a million remotes and radios this way

Sent from my iPad using PhantomPilots mobile app

Flying Dutchman · Feb 10, 2016

Wow that is really strange. How did you notice?

dsd317 · Feb 10, 2016

Flying Dutchman said:
Wow that is really strange. How did you notice?

My controller sounded like a rattler. Very annoying!

Rasit · Feb 10, 2016

Dave from Ok said:
Just get a hot glue gun from a hobby store. Fixed a million remotes and radios this way

Man that's a lot of remotes!

Sinisalo · Feb 10, 2016

if he fixes it with plast aid he will still be able to take the remote apart because he will simply be gluing the threads back together or making new threads.

TheLightSpeedz · Feb 10, 2016

I had the same problem when I put my DBS ITELITE kit on. I just keep it snapped together

Sent from my iPhone using PhantomPilots mobile app

rene van der meer · Feb 10, 2016

dsd317 said:
I've heard of problems with DJI controllers cracking, but all four of my threaded holes that keep the controller halves securely fastened are either cracked and/or damaged beyond repair.

The only thing (aside from buying a new controller) I can think of doing is to use longer screws. The problem is that it would add more stress due to the gap from the missing pieces from the areas where it completely cracked off.

Any other suggestions?

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dsd317, did you open the RC or was it in its original state?

NoOne · Feb 10, 2016

My controller had thread post pieces rattling around in it since day one. Then the lanyard clip broke the other day while I was walking with it sending it and my iPad Air 2 tumbling to the pavement, breaking the antennas off the remote, the rest of the thread posts and cracking my iPad. I've currently used 1 minute epoxy on the case female thread posts and on the knob servo female posts that broke. Waiting a few days for it to harden to drill new pilot holes that I'm hoping will rethread with the existing screws.

dsd317 · Feb 10, 2016

rene van der meer said:
dsd317, did you open the RC or was it in its original state?

I've installed DBS mod a few months ago, so I've opened it once before. At that time, only one post cracked completely off. In fact, the post in my first photo is that exact same one. I just Krazy glued back onto the post. It held really well.

The other post (4th photo), separated into a few pieces. Which is what made those annoying rattling noises.

I've been working with RC stuff for many years without over-tightening plastic parts, so please don't think I over tightened them, or screwed them up the wrong way. I go as far as making sure I place the same screw into the same threaded hole it came from, and will not continue to tighten screw if I feel any unnecessary resistance. This way I know the thread is following the same path, and not creating another path.

dsd317 · Feb 10, 2016

NoOne said:
My controller had thread post pieces rattling around in it since day one. Then the lanyard clip broke the other day while I was walking with it sending it and my iPad Air 2 tumbling to the pavement, breaking the antennas off the remote, the rest of the thread posts and cracking my iPad. I've currently used 1 minute epoxy on the case female thread posts and on the knob servo female posts that broke. Waiting a few days for it to harden to drill new pilot holes that I'm hoping will rethread with the existing screws.

Sorry to hear that. Let me know how well that epoxy holds up. Post pics if you can.

dsd317 · Feb 10, 2016

Sinisalo said:
If you use Plast-Aid I can guarantee you it will work to permanently fix your problem. I have used plast-aid for so many things around my house it is crazy. It bonds to the plastic chemically and physically. I got mine from Amazon, here is the Plast-Aid marketing video:

You could even use plast-aid to form new threads

This looks promising. I wonder if anyone with these bad controllers have used Plast-Aid.

NoOne · Feb 10, 2016

Dave from Ok said:
Just get a hot glue gun from a hobby store. Put a few blobs around the edges and hold the case together until it cools. You will still be able to open it if you have to with some pressure and a butter knife. The excess is easy to remove so cosmetics are not a problem. Fixed a million remotes and radios this way

Sent from my iPad using PhantomPilots mobile app

This seems like a good idea because you can reopen the glued case if necessary in the future. Do you have a hot glue recommendation? I see that Titebond HiPur glue on my web searches but that seems like an expensive system for a one time use scenario such as this.

Sinisalo · Feb 10, 2016

NoOne said:
This seems like a good idea because you can reopen the glued case if necessary in the future. Do you have a hot glue recommendation? I see that Titebond HiPur glue on my web searches but that seems like an expensive system for a one time use scenario such as this.

With plast aid you can still re open the case because you are not gluing the case shut but rather just fixing the threads so it will work the same as new

NoOne · Feb 10, 2016

Sinisalo said:
With plast aid you can still re open the case because you are not gluing the case shut but rather just fixing the threads so it will work the same as new

Well that's essentially what i'm trying to accomplish with the 1-minute epoxy. I have set the epoxy in the female thread posts. I will then drill a pilot hole and see if the screw can create new threads to bite into.

Mordor · Mar 8, 2016

I have a big crack on my RC (P3A), it appear from nothing......damm it!

happydays · Mar 8, 2016

One of our local guys had the right stick fall completely inside the controller and lock the phantom in full speed forward flight. He managed to yaw it around and do circles while attempting to get the stick back out again. Eventually it worked loose and he was able to get the aircraft back under control. Turns out all of the threads holding the stick in place had stripped and the stick dropped into the controller body. Scary stuff!