Best way to reenforce thin broken parts?

[RobRomero]

I have found regluing thin broken parts such as propeller blades or ships masts an unsatisfactory fix as they are often easily broken again. I’m thinking of buying thin brass rods to drill in as support and reinforcement. If you think this is a good method, could you recommend the THINNEST PRACTICABLE BRASS BARS (OR OTHER MATERIALS) to do the trick. Also how would you recommend cutting the bars so they don’t get bent and have a clean smooth cut without a “burr”
If you have any other BETTER recommendations to reenforce thin broken parts, I’d be grateful.

Thanks for your consideration!

Rob

[digger303]

I use flush cutter pliers. They give a straight cut, but can still give some squashing of the ends. I generally just do a quick clean up with a file. Soft metals only with these pliers. Materials like piano wire require more force to cut and should be done with proper wire cutting pliers or a cut off disc. Both will require a quick touch up with a file of the ends. Dress making pins are a good source of rod for certain things.
The biggest problems with this method of drilling a hole and inserting rod is not breaking the part because the drill is too big in relation to the part your drilling and it twists the plastic off, breaking the drill bit because of carelessness. Also when strengthening a existing part getting the 2 holes ...one in each piece...aligned is can be difficult. So I suggest make it a little over size to allow for this fill with glue and join. Tricky bit getting them to stay straight while the glue is curing.
The other way is to replace the plastic entirely with metal rod and if visible can look much better.