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Instant Replay Vinyl Overlay Replacement

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CAUTION: Metal components will become HOT during this process. Handle with care and with proper safety equipment.

Applies to:

Instant Replay models: DR-550/552/554/600

Symptom:

Vinyl overlay is damaged.

Possible Reason(s):

Various

Solution(s):

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  1. Disassemble the top panel.
    1. Remove the top panel from the main chassis.  (See KB article for general disassembly of an Instant Replay.)
    2. Remove all components from the top panel.   This include the display, meterboard, keyboard and rubber keypad.
    3. The only thing remaining should be the metal and overlay.  (Normally, the plastic bushings at the top of the panel will survive the process but it would be good to remove them as well.)
  2. Remove the old overlay
    1. The overlays us a very aggressive adhesive which will take effort to remove.   To loosen the adhesive, warm the panel before attempting to remove the overlay.
      1. Preheat an oven to approximately 225 degrees F.
      2. Bake the top panel for 3 to 5 minutes.
      3. CAUTION the panel will be hot when removed from the oven.  Use protective gloves when handling.
    2. Place the hot panel on a hard flat surface that will not melt.
    3. Start with the upper left corner and peel the overlay diagnally.   
    4. At about half way, start to peel from the lower left corner.  
    5. In some cases, continuing to peel off the old overlay in this manner is sufficient.
      1. If it becomes difficult, try peeling from the upper right corner where the display would be.
    6. Once the overlay is removed, the sticky adhesive residue will remain on the top panel.   This is generally ok as long as there are no lumps of adhesive.
  3. Installing the new overlay.
    1. Make sure the top panel is clean and free of any lumps or debris.   Clean as needed.
    2. Start with the overlay face down on a flat surface.
    3. CRITICAL STEP: Remove the adheaseve backing material in an "L" shape around the corner where the display would be.  Do not remove any other areas of the backing material.
    4. Place the overlay lightly on top of the panel aligning the left side to make sure the square Hot-Key button holes are aligned.   
    5. Align the three level / headphone volume holes on the right.
    6. Once everything is aligned, press down on the upper right corner where the display would be and where the backing material was removed.   This will provide the alignment for the next steps.
    7. With the upper right corner secured, lift the overlay and remove all remaining backing material.
    8. CRITICAL STEP:  With the remaining overlay up in the air, above the panel, allow it to gently float into place.
      1. The above step may take a couple of attempts. 
      2. Do not put any pressure on the overlay or try to smooth it as it is laying down.  
      3. If the overlay does not float into place, lift it off the panel from the left and again let it gently float onto the panel.
      4. Repeat until the holes in the panel are properly aligned with the overlay.  There should be no bubbles or odd spots before proceeding.
    9. Press down on the overlay in a smoothing motion from right to left and then center to top and center to bottom until all of the areas are stuck to the panel.
  4. Although not generally required, sometime the overlay will overlap the edge of the panel.   If desired, a razer blade can be used to trim the over overlay as needed.
  5. Reinstall all of the components previously removed and reinstall the top panel.
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