My fix for clamp stress cracks #5626094 - 01/16/13 12:14 PM Attachment (32 downloads)
First, thanks to all who offered comments and suggestions.
I decided to go with stainless steel worm clamps around the plastic that encloses the brass inserts (see photo). This fix was cheap ($2 per clamp) and easy to do. The clamp should prevent further splitting and separation of the plastic.
Even so, overtightening the screws could still cause the brass insert to pop out. Midnight Dan is quite correct that very little force is needed to hold the leg extension securely (about 1/4 turn after feeling initial resistance).
Re: My fix for clamp stress cracks
[Re: Midnight Dan]
#5630506 - 01/18/13 07:59 PM
This may be overkill, but you could try drilling a 1mm (.04") hole thru the side of the plastic boss into the brass insert. Then insert a 1 mm diameter stainless steel pin thru (with some glue) the hole effectively cross pinning the insert.