I have a situation that I need help with. I have a big bunch (3k) of brushes that need better tuft retention for a special application. The brushes are 7" long x 3-1/2" wide and have 50 holes/tufts in them. Each hole is 1/2" deep x 9/32" dia. and each tuft is 3 flat wires bent 180 deg, and stapled into the hole with a 18 ga., 1/4" crown x 1/2" leg staple. I am thinking of injecting glue of some kind into the hole with the wire. These brushes are already made. If I can inject glue or epoxy into the holes, the material will have to be able to withstand the brushing action and not crumble or pop out. I wonder if carpenter's glue would work. I'm looking for leads for some type of powered dispenser too. My budget needs to be under a buck apiece including labor.
Apparently, the action of the brush in this application is way different than normal. They use the brushes in a linear motion that is parallel to the staples. They use the sides of the flat wire to break spoo up rather than the face of the flat wire to "sweep" like a normal use. This action has a tendency to rock the staples out even though the tuft retention is over 40 pounds pull-out strength. (Where's that Unabtaniun when I need it!)