Abstract: A method of repairing a spent printhead or printhead subassembly and a repaired printhead or printhead subassembly made in accordance with such method is disclosed. The method includes the steps of removing the print pins from the spent printhead or printhead subassembly, removing at least a portion of the nose section in the area of the print pin holes of the spent printhead or printhead subassembly, filling at least a portion of such removed portion of the nose section with a casting material, inserting guide wires into the print pin holes in the nose section and permitting the casting material to at least partially cure to form new print pin holes.