The nylon bush is a common problem Is should expect in most vacs that use the same design, the constant movement of the handle back and forth creates the friction that wears the bush down. A bit of spray grease on the bush applied on a periodic basis should help prevent this type of wear. As for the chassis or housings splitting, there's not a lot you can do here except try to repair it with superglue or other epoxy resin, or replace the cracked parts - difficult to obtain now though on such an old plastivac.
I may try your solution though on the bush support screws, longer ones would certainly help. Am loathed to use superglue or araldite to glue them in permanently in case I ever need to remove them again.
Benny, on the subject of the brushrolls, I beleive the old Senior range were supposed to be fitted with a king of H clip beween the chassis and the brushroll to stop vibration rattle - are the TP1 models which use the same type of roller bearings supposed to have these H clips fitted as well? my brushroll makes a terrible racket when pulling the cleaner backwards, but stops when pushing forwards. There is wear in the bearings, but the brushroll seems to spin round reaonably quietly when standing idle and the motor running. There is not a H clip fitted between the end of the brushroll and the chassis. My Ranger doesnt have one either, but I've seen them on Ebay and wonder which models should have one fitted.
