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Since I bought my little aluminium case I've only ever been impressed by it. Now, however, the metal outer frame is separating from the panels on the undermost side. Long story short, I'm worried about it breaking fully.

Do, Dakka, what should I do/ what would you recommend? I bought it long ago, so I suspect any warranty it may have had would be long expired. Should I look into finding myself a glue gun and hammer? Has anyone encountered something like this before from KR?

Low-res webcam image attached for reference.

I’m not sure what their warranty is like, but there is not hard in firing them an e-mail describing the problem and asking for advice.

Barring that, I’d try hot glue or gorilla glue. But that’s just my uninformed guess, and my first thought if it happened to me.

Speak to KR, they have always had good service when I have had issues.

Tell them about it. They're either tell you you've caused it yourself, or deal with it for you.

I had a similar issue with a Kaiser backpack, where the fabric panel between the 'bays' had pulled away from the top handle.
After sorting it out with a CS bod who left my problem in limbo, it got sorted out in the end.
I had to ship my bag back, and got a replacement added to an order I put in with them. Returns postage for dealt with too, IIRC.

Send them photos, and keep records of all emails, phone-calls and letters.
Not 'cos it is KR, but just as a matter of course. I had to chase them in my case, but only due to the person leaving before the finish.

KR customer service is usually top notch, I would expect them to deal with this to your satisfaction or a least advise you on how best to fix it.

Give them a call.

If worst comes to worst, use two part epoxy instead of a hot glue gun.

^ +1.

I wouldn't use hot glue for ANY case repairs (not even to the foam trays). It's just not strong enough.

+2 to Vertrucio. I would of course ask KR what they suggest first, but 2 part epoxy or gorilla glue and a couple of clamps should take care of that problem easily.

I would try not to use a hammer. If you do need some impact, use a rubber mallet or at least a piece of wood wrapped in a bit of foam, in order to deform the case and edges as little as possible.

Good Luck.