I strongly recommend replacing the shell. If you've got a problem with a cheap, welded shell you will probably have others down the road. Polyline Corp. used to sell very high quality, clear empty cassette shells. They still sell bulk-loaded clear shells, and the prices are so low that it would actually pay to throw out the tape and just use the shell:
I don't know if these are the same clear shells I bought from them back in the 1980s, but they certainly look very similar. The only issue is that they have a minimum order of 100. But, if you're in the business, it would be good to keep a stock on hand. Who knows how long they'll be available?
They note that the bulk-loaded tapes are special order, requiring 1-3 days. This may mean that they load the tapes to order, which may mean that they'll sell you the empty shells. It would be worth contacting them to ask.
Audio Engineer Emeritus
The Crane School of Music
SUNY at Potsdam, NY 13676
"Great art presupposes the alert mind of the educated listener."
"A true artist doesn't want to be admired, he wants to be believed."
From: Association for Recorded Sound Discussion List [mailto:[log in to unmask]] On Behalf Of Jeff Willens
Sent: Wednesday, June 28, 2017 4:52 PM
To: [log in to unmask]
Subject: [ARSCLIST] Cassette repair question
Does anyone have a conservationally sound method for reattaching felt pressure pads to cassette shells? I'm loathe to use Crazy Glue as I have no idea if it seeps through the felt. Double-stick tape was also mentioned to me, but I can't see that standing up to playing.
Replacing would be fine unless the shell is sealed. I would prefer to not have to break the shell to get inside. But if I have the pad, I'd like to reuse it somehow. Any thoughts?