It does have metal in it.
I expect the plastic to break first, but it actually seems to be more stretching on the Pandora when forced, I can see stress marks starting to appear if I force the screen past the final click now. I'm just sitting here flipping the Pandora open and closed (holding the base and violently flicking the top part up and down) as it's the easiest way to force it back past the final click. I occasionally force the top part back hard and hold it there too as far as I can push it.
It still works perfectly. The stretching has not got any worse in the last 500 or so slams.
I keep seeing these DS hinge replacement parts for sale, it worries me that Nintendo can't even get their hinge 100%.
How many do you think is a reasonable amount to try to do? I'm thinking a well used Pandora might be opened and closed 15 times a day.
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You reminded me of something I noticed. After taking a couple of Nintendo DS's apart I noticed a difference in the older hinge design and a newer DS lite. The left hinge has a small metal bushing that fits between the lower hinge socket and where it connects to the top lid hinge socket.(The ribbon cable from the top LCD ribbon cable has to come through it). Anyway I'm unsure if this was the cause of the original problem but that little bit of give could have cracked the plastic around the hinge due to less uniform force.