Zipper FXR Instructions

Nothing is more frustrating than a zipper that won't stay closed. This tool was designed (and used) by an Alaskan hunting and fishing guide to restore tooth or coil type zippers to their original function. Zippers come in a variety of sizes, and this particular model of the Zipper FXR is designed for repairing the most commonly used zippers (sizes 5-10) found on most backpacks, outdoor garments, gear bags, rain jackets, tents, and of course AIRE inflatables. However, this Zipper FXR model can be used to repair smaller or larger zipper slide assemblies using a procedure discussed in the following repair instructions.

The two key parts of any zipper are the slide assembly and the teeth, or coils. The slide assembly guides the teeth or coils together and facilitates the locking of the opposing sides of the zipper tracks. The first step in the repair process is to inspect the teeth or coils on the opposing tracks of the zipper tape. Look for damaged or missing teeth segments or coils. Damage to tooth type zippers generally have missing teeth segments and are easy to observe. Coil type zippers are made from a continual spiral of plastic that cane be crushed, distorted, or broken to a point where they will not mesh and lock with the opposing coil when passed through the slide assembly. Missing or damaged teeth or damaged, crushed, or distorted coils will require replacement of the entire zipper assembly as no other repair is practical. If the teeth or coils are serviceable, the problem is with the zipper slide assembly.

The slide assembly is designed with an internal tolerance that insures the proper meshing and locking of the opposing teeth or coils. Zippers will separate if this slide tolerance becomes excessive, which generally results from being distorted by forcing the slide over adjoining fabric not part of the zipper track. The Zipper FXR is designed to return the slide assembly to it's working tolerance.

Inspect the slide assembly for obvious damage. If the slide is distorted or bent to the point where it will not accept the teeth or coil tracks, use the "spurs" on the handle end of the Zipper FXR to gently open the slots on the opposing sides of the zipper slide just enough to accept the zipper tracks. Do not over do this procedure or permanent damage to the slide may result such as breaking the slide assembly apart. NOTE: Lower quality zipper slide assemblies are made from brittle metal material or plastic. Brittle metal slides have a tendency to break in half when trying to return them to their original shape. Plastic zippers, once distorted, are very difficult to almost impossible to restore to their original function. Consequently, repairs to lower quality slide assemblies made from materials mentioned above is a matter of haiving nothing to lose but try a repair and hope for a fix. Fortunately, most high use zippers utilize high-quality slide assemblies which respond easily to repairs.

REPAIRS: After determining that the teeth or coils are serviceable, and the opposing zipper tracks can pass through the slide assembly slots, return the slide assembly to it's original starting position. This may take some time to do if the zipper has separated some distance up the zipper track and the teeth or coils have become misaligned. Do not apply excessive force that may cause damage to the teeth or coils. Generally a walking-type motion down the opposing zipper tracks with the slide will return the slide to the starting position. If the zipper becomes completely jammed during this process, use the handle "spurs" to relieve the jam within the slide. Be careful not to cut or damage the track tapes holding the teeth or coils when using the "spurs". With the slide assembly returned to the start position, ensure the guides on the end of each of the opposing zipper tracks are fully engaged into the slide assembly. With the zipper halves fully engaged into the slide assembly, position the Zipper FXR jaws over the slide assembly and apply pressure.

NOTE: The jaws of the Zipper FXR should be positioned on the top and bottom of the slide assembly with the slot between the jaws straddling the center fixture on the slide assembly. The jaws must be positioned on the trailing 1/2 to 2/3 portions of the slide assembly as this is the area that locks the teeth or coils together. The forward or wider front portion of the slide assembly serves only as a guide to position the opposing zipper tracks into the slide assembly for final meshing and locking of the teeth or coils. DO NOT apply tool pressure to this portion of the slide. DO NOT apply excessive pressure, but rather apply successive pressure applications to the jaws after checking for proper zipper function after each pressure application.When checking the proper zipper function, be sure the teeth or coils at the very beginning of the zipper tracks are properly aligned or the zipper will inevitably separate again. If the teeth or coils are not all fully engaged and aligned, return the slide assembly to the initial start position and begin again. Although the internal function of the slide assembly of zippers has remained the same over time, the outer structures on some models have become more elaborate and ornamental in design. On slide assemblies where the Zipper FXR can not be positioned over the slide with all four jaws engaged, position the tool to engage one side of the slide and apply pressure. Alternate the process to the opposing sides of the slide assembly the repair is facilitated. A repair should be conducted by applying slight tool pressure followed by testing the zipper for proper function after each pressure application.

If the zipper does not respond to several repeated pressure applications and continues to separate, move the slide a few teeth or coils up the zipper track from the start position and repeat the tool pressure and subsequent functional checks. Failure to properly function after the above procedure indicates the slide assembly is excessively worn internally and is no longer capable of locking the teeth or coils together, or the teeth or coils are excessively worn. Replace the slide and/or the entire zipper assembly.