First a little background on the project:

I recently got a brand new Sears bug zapper. Its a model from the late 70s or early 80s. It worked great for a few weeks then one night it wasnt zapping. Upon inspection of the unit after removing power, I found one of the 4 plastic grid insulators was burned. These little plastic insulators are what hold the entire HV grid in place. Unfortunately, Sears no longer sells the insulators as shown here # 33 http://www.searspartsdirect.com/par...7/1500155/00023776/00001?blt=06&prst=&shdMod=
http://www.searspartsdirect.com/par...7/1500155/00023776/00001?blt=06&prst=&shdMod=

So, my new zapper is dead because of one simple piece of plastic. I want to make some new ones. Would HDPE work in this application?

 

Probably. What do you have to lose? 15 minutes of carving a spacer?

Most plastics will work. Any spacer can be ruined by a carbon track running along it. These things are common enough if a bug lands on a spacer. It's not a big deal.

 

hot glue works also. just use the hot glue gun to make a blob to replace the broken insulator.

 

got a broken toaster lying around? the wafer that holds the element would be a good insulator, designed for heat.

edit: drill required holes in it to depth you need and easy to cut with scissors.