OK, it's been a while, but I'd like to share my device's fate and my thoughts. Disclaimer: This is no complaint. Just a report of my experiences that can hopefully be learnt of. I still like my PBP and hope the PBP will evolve into a robust, reliable and sustainable device. The issues I experienced may not apply to all PBPs. I do conclude though that the current mechanical design is not good enough. It is not up to the task.
So here's what happened in the meantime. I glued the cracks with epoxy and re-enforced the case around the cracks with thin fiberglass tissue (used in drywall construction) soaked in epoxy.
On top of the cracks in the case, the spacers had broken into pieces. I measured the remains and found that the hole grid PCB I had lying around had almost exactly the same thickness. So I drilled two holes for the screws and cut out two pieces, both a little larger than the original spacers. I also tried lubricating the hinges again with some universal grease. I did not notice any relief, though.
My fix lasted a few weeks before the cracks cracked again. This happened while I was on vacation so I had no chance to immediately fix the case again. By the time we got back home, the entire edge of the case had broken off. The brass inlays had broken out of the plastic posts. It looked very much like on the pictures @
vfr400racer posted.
When I read about the availability of the replacement cases I ordered one and it arrived recently. Despite the hope the "new" pIastic really turns out to be less brittle, I decided to re-enforce the spots the hinge plates get screwed onto by filling the voids with epoxy.
I managed to transfer all components to the new case except for the touchpad. Its glued into place with strong double sided tape as it seams. And I was afraid I could damage it by applying too much force. Does anyone have a tip how to safely uninstall the touchpad?