I replaced one of the broken DT16 bills with one I made from 1/8" lexan, and anchored with D2T epoxy.
It feels very solid.
I traced the original bill, cut it out on the bandsaw, shaped it with the occilating belt sander, and also used the sander to thin the leading edge.
I use sst welding wire for the line tie. This was my first time putting a line tie in a bill, and I used the dowel hole from the original bill to anchor the wire back into the bait.
All of the ideas came from here, so thank you all.
I just finished it, so I don't know how it swims yet. I'm taking it out Thursday for a test drive.
I posted pictures in the hardbaits gallery.
I checked some new DT16s that I have, and they also have strange looking clouding around the line ties.
I suspect whatever process they use to either manuf. the bills themselves, or to anchor them, heats the metal line tie, and results in stress in the plastic bill, since that's the point where they all break.
Is it designed obsolescence, or just arrogance, that keeps Rapala from correcting this obvious defect?