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09-15-2020, 05:05 PM - 3 Likes   #1
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Pentax AF-540FGZ Flash battery door repair

Common problem. This was my recent fix. It might help someone else.
Aim:
Replace battery door static plastic tabs with metal versions
Process:
Disassemble flash rear panel from the flash unit by removing two screws rotating the flash swivel head and two screws at the bottom for the hot-shoe whilst loosening the other two hot shoe screws. The hot-shoe screw holes assembly extends below the case assembly so need to be pulled out and away in order to release flash rear panel.
Manufacture new tabs assembly:
From a discarded cut and opened metal food container cut a flat section of metal sheet about 40mm x 5mm. The tabs will be longer than required.
Bend this to a length of angle along the centre line.
Measure and cut out tabs along one side using the battery compartment tab moulded cut outs as the measurement guide. Use Dremel (or similar) cut off wheel.
Cut the section out between the tabs down into the metal backing plate of the tabs by a small amount to allow assembly to be held by case shoulder for the tabs yet to be cut. Use Dremel cut off wheel and flat file for cleaning the cut surfaces.
Ensure that the newly created metal tabs section fits well against the battery compartment and tabs fit well in the plastic tab indents. The tabs are likely to be a little long at this stage.
Modifying flash rear panel plastic tabs sections:
Changing the Dremel tool to a highspeed cutter. Running at lower speeds so as not to burn the plastic. Cut out the old plastic tabs and up into the flash housing a small amount in order to create a shoulder for the metal tabs to sit against. The depth of these shoulders is the thickness of the battery compartment lip with tab indents plus metal thickness. This presents a mechanism to hold the metal tab assembly in place without the requirement of any adhesives and keeps good structural integrity for the tabs and the flash unit.
Clean cut surfaces with a small file.
Place the metal tabs assembly against the battery compartment whilst assembling the rear panel back in place to the flash unit. Insert screws and tighten firmly.
Whilst gently noting the battery door edge against the tabs very slowly cut / grind the tabs down so that the door internal edge can be close past the metal tabs. Do this slowly as the plastics can easily be over heated.
Insert batteries and your good to go for normal operation.

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09-15-2020, 05:59 PM   #2
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I don't own one of these flashes, but wanted to say great job on describing your repair technique.
09-15-2020, 06:52 PM   #3
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Better than the tape some use that's for sure.
09-15-2020, 07:31 PM   #4
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I've been using a ziptie to keep my AF360FGZ door shut for years..
slides on and off for battery swaps

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