(My apologies in advance for some of the poor quality images!) When you first opened your DNA Design DK-06 Upgrade Kit... and fitted it onto your Studio Series 07 Leader class Grimlock, did you find that the following parts were defective/damaged?: A) Rivet hole of the spiked mallet connector pole incorrectly drilled? B) Handle of the mace with chain broken in the middle of rectangular peg hole because too much force was applied upon disassembly? C) Articulated tail jutting out to the left? Left robot arm crooked as it holds the tail? D) Second segment of articulated tail not swinging to the right? Never fear nor waste more money buying a new kit! The following fixes I’ve made to my own kit are sure to repair and improve your own! Materials/Tools needed: Dremel 7300 MiniMite Cordless Rotary Tool Dremel 105 1/32" Engraving Cutter Dremel 404-02 1/2” Nylon Bristle Brush Dremel 411 Sanding Disk 180 grit Dremel 7122 Diamond Wheel Point Dremel 7105 Diamond Wheel Point Dremel 83702 Silicon Carbide Grinding Stone Dremel EZ476 EZ Lock™ 1-1/2" Cut-off Wheel Dremel Drill Bit Set 3M Imperial Wetordry 800 Grit sandpaper 3M SandBlaster 180 Grit sandpaper K&S Precision Metals #87131 Stainless Steel Rod 1/16 Loctite Liquid Super Glue Long, straightened paper clip Old, yet clean toothbrush Short spike x3 LEGO Black Bar 4L (Lightsaber Blade / Wand) X-Acto #11 CHAPTER A 01) Split spiked mallet in half, then set aside mallet half that does not hold connector pole. 02) Carefully push out rivet, then set rivet and mallet half aside. 03) With the Dremel 7300 MiniMite Cordless Rotary Tool, use the following Dremel Drill Bits at low speed in descending order… a) 1/16” b) 5/64" c) 3/32” d) 7/64" e) 1/8" and the Dremel 7122 Diamond Wheel Point at low speed to make a wider hole on rivet joint for a LEGO Black Bar 4L (Lightsaber Blade / Wand) to fit through. (in my case, I used a junk LEGO Black Minifigure, Weapon Lance.) 04) With the Dremel 7300 MiniMite Cordless Rotary Tool, use the Dremel EZ476 EZ Lock™ 1-1/2" Cut-off Wheel to carefully cut off ends of bar as close as possible to the rivet joint. 05) With the Dremel 7300 MiniMite Cordless Rotary Tool, use the Dremel 83702 Silicon Carbide Grinding Stone, then the Dremel 404-02 1/2” Nylon Bristle Brush to sand and smooth down the ends at low speed, then use the Short spike to carefully push a “crater” in the very middle of the joint on both sides. 06) With the Dremel 7300 MiniMite Cordless Rotary Tool, use a 1/32” Dremel Drill Bit, then a 3/64” Dremel Drill Bit at low speed on each side to carefully drill the new rivet hole. 07) Before permanent reinstallation, use a longer rivet that’s the same size as the original one to temporarily install the connector pole to see of it goes down all the way to the “trench” on the mallet half. It not, use pliers to pull out longer rivet, set connector pole aside, and use the Dremel 7105 Diamond Wheel Point at low speed to carefully deepen & widen the “trench” enough to ensure that the connector pole fits all the way down in it. 08) With the Dremel 7300 MiniMite Cordless Rotary Tool, clean/polish connector pole with the Dremel 404-02 1/2” Nylon Bristle Brush at low speed. 09) Boil some water, then dip the mallet half where the connector pole is placed in a few times until the white stress marks on the lower rivet hole disappear. 10) Clean & dry the mallet half from top to bottom with old, yet clean toothbrush. 11) Reinstall the connector pole in the mallet half by inserting and pushing the original rivet at the top of the mallet where the bigger spikes are. 12) Connect both mallet halves and your done here! CHAPTER B 01) Use the Short spike to carefully push a “crater” in the very middle of the broken ends and at the bottom of the handle. 02) With the Dremel 7300 MiniMite Cordless Rotary Tool, use the following Dremel Drill Bits at low speed in descending order… a) 1/32” b) 3/64" c) 1/16” to carefully drill a long shaft through both ends of the broken end of handle first, then through main half of handle for a K&S Precision Metals #87131 Stainless Steel Rod 1/16. 03) Use an X-Acto #11 razor blade to carefully slice off plastic bottoms of the rectangular peg holes. 04) Before inserting rod in main half on handle first, use the Dremel 7300 MiniMite Cordless Rotary Tool with the Dremel 411 Sanding Disk 180 grit at high speed to sand down the edges so that the rod can be inserted smoothly into the long shaft made through main half of handle. 05) Use a Long, straightened paper clip to apply Loctite Liquid Super Glue inside long shaft made through main half of handle. 06) Quickly insert rod into long shaft made through main half of handle. 07) Thread the broken end of handle through the rod to check where and how it correctly fits onto broken end of main handle. 08) Move the broken end of handle far, yet close enough from the main handle in fitting position, then use toothpick to carefully apply Loctite Liquid Super Glue at medium length on rod starting at broken ends of main handle. 09) While in the fitting position, carefully move the broken end of handle down to the broken end of the main handle. Use force to correctly align the rectangular peg holes. 10) With the Dremel 7300 MiniMite Cordless Rotary Tool, use the Dremel EZ476 EZ Lock™ 1-1/2" Cut-off Wheel at low speed to carefully cut off rod close enough to the bottom of handle. 11) With the Dremel 7300 MiniMite Cordless Rotary Tool, use the Dremel 83702 Silicon Carbide Grinding Stone to carefully flatten down broken end of rod. 12) Use a small-cut sheet of 3M SandBlaster 180 Grit sandpaper to carefully remove dried films of glue on whole handle. 13) Clean inside of rectangular pegs with the Old, yet dry toothbrush, then use the X-Acto #11 razor blade to carefully grout out dried glue from inside edges of rectangular pegs. 14) With the Dremel 7300 MiniMite Cordless Rotary Tool, use the Dremel 105 1/32" Engraving Cutter at low speed to carefully remove dried glue from the “trench” in the middle of broken ends to make it as pronounced as the others on the handle. 15) Use a small-cut sheet of 3M Imperial Wetordry 800 Grit sandpaper and the Dremel 404-02 1/2” Nylon Bristle Brush to polish bottom end of handle, then the rest of handle. 16) Clean whole handle with the Old, yet dry toothbrush and your done here! CHAPTER C Since the handle for the part that connects the spiked mallet with the spear weapon is the same design as the handle for the chain mace, it was prudent to install the same stainless steel rod in the core of the connector part to prevent it from breaking from force. 01) Use the Small spike to carefully push a “crater” in the very middle of the bottom of the handle. 02) With the Dremel 7300 MiniMite Cordless Rotary Tool, use the following Dremel Drill Bits at low speed in descending order… a) 1/32” b) 3/64" c) 1/16” to carefully drill a long shaft straight through the core of the handle for the K&S Precision Metals #87131 Stainless Steel Rod 1/16 that was used for CHAPTER B. 03) Use the X-Acto #11 razor blade to carefully slice off plastic bottoms of the rectangular peg holes. 04) With the Dremel 7300 MiniMite Cordless Rotary Tool, use the Dremel 411 Sanding Disk 180 grit at high speed to sand down the edges of the uncut end so that the rod can be inserted smoothly into the long shaft made through core of handle. 05) Use the Long, straightened paper clip to apply Loctite Liquid Super Glue inside long shaft made through core of handle. 06) Quickly insert rod into long shaft made through core of handle. 07) With the Dremel 7300 MiniMite Cordless Rotary Tool, use the Dremel EZ476 EZ Lock™ 1-1/2" Cut-off Wheel at low speed to carefully cut off rod close enough to the bottom of handle. 08) With the Dremel 7300 MiniMite Cordless Rotary Tool, use the Dremel 83702 Silicon Carbide Grinding Stone at low speed to carefully flatten down broken end of rod. 09) Clean inside of rectangular pegs the Old, yet dry toothbrush, then use the X-Acto #11 razor blade to carefully grout out dried glue from inside edges of rectangular pegs. 10) Use a small-cut sheet of 3M Imperial Wetordry 800 Grit sandpaper and the Dremel 404-02 1/2” Nylon Bristle Brush at low speed to polish bottom end of handle. 11) Clean whole handle with the Old, yet dry toothbrush and your done here! CHAPTER D 01) With the Dremel 7300 MiniMite Cordless Rotary Tool, use the Dremel 83702 Silicon Carbide Grinding Stone at low speed to carefully sand down the inner right side where the back of left robot mode hand until the hand fits straight and the whole tail is linear with the rest of the T-Rex mode. 02) Use a small-cut sheet of 3M Imperial Wetordry 800 Grit sandpaper, then the Dremel 404-02 1/2” Nylon Bristle Brush at low speed to polish sanded down inner right side. 03) Clean inside of tail with an old, yet clean toothbrush. 04) Fit the tail on the figure in T-Rex mode and you’re done here! CHAPTER E 01) Carefully remove the rivet at the joint between the main and second segment and set the second and third segments aside. 02) Turn the tail over and carefully sand down the left side of the semi-circular joint with the Dremel 7300 MiniMite Cordless Rotary Tool and the Dremel 83702 Silicon Carbide Grinding Stone at low speed. 03) Use a longer rivet that’s the same size as the original, smaller one to temporarily reinstall second segment to main segment to check if the second segment of tail can be positioned left after the left side of the semi-circular joint has been sanded down enough. 04) Use a small-cut sheet of 3M Imperial Wetordry 800 Grit sandpaper, then the Dremel 404-02 1/2” Nylon Bristle Brush to polish sanded down left side of semi-circular joint. 05) Use an old, yet clean toothbrush to clean main segment of any dust. 06) Turn tail back over, place second and third segment of tail back in, then insert rivet back in through the rivet hole on top of tail. 07) The tail can now move fully left and right. ALL DONE!!!
Mine had this issue as well, but I dipped it in boiling water for about 20 seconds and flexed the joint back and forth until it stayed in place. No disassembly needed!