I'm really tempted to say we should be looking at these vacs under crossed-polars. Strain in plastic and glass (as long as they are amorphous) can be seen in the presence of two polarized lenses 90 degrees rotated from each other. I really wonder if perhaps there isn't strain in the barrels of some of these pens... if they were machined inside, it's quite possible this is the case. If they were molded and cooled too quickly, this could also be the case. [The same goes for stresses related to solvent welding and evaporation.]
It shouldn't be too difficult to do. I'd grab 2 sets of sunglasses, both polarized... I'd punch out one eye from the crappy pair, and place it in front of a good strong light (don't set it on fire!), then don the second pair of sunglasses. By rotating the first, and placing the pen in between the two sunglasses lenses (light, lens, then pen, then lens, then eye). If stress is present, you'll see it as a rainbow of colors radiating from the point of stress. You'll likely have to turn one sunglass lens 90 degrees to the other (make it look black before putting the pen in between).
Example of polarized light through an amorphous clear medium.The above URL may not be the best example. If I come across a better one, I'll let you know. If you have any clear plastics lying around (the best is likely very thin acrylic), you can test our your little stress rig by bending the plastic and seeing if you can see any stress inside it.
This of course doesn't help any of these breaks, but I'm wondering if stress isn't happening if simply setting some of these down on the table will cause fractures!
I've got an old Vac here waiting to be restored, but it's not cleaned enough to see through the clear portion very well. If I can manage that, I'll attempt this myself and if that works, I'll try and post pictures. [don't wait around for that post, though, I'm super busy- so it's last on the list right now]
Let me know what you think of this- and if anyone has ever tried viewing the stress in these plastics!
-Allen