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A co-worker of mine was reusing tapes to save $$ on his budget. Saved about $100 in tapes. Cost him about $1600 in repairs to his deck and camera.
Specifically what damage was done to the deck or camera that you can be sure was directly caused by reusing tapes?
I'm not an engineer, but it would not surprise me to learn that repeated use of a tape degrades performance of the lubricant (I'd be surprised if it didn't really). I would also think that repeated use would loosen the particles on the tape, and cause more clogs and such.
I'd much rather use a less expensive tape once, than a pricey tape twice (or more).
Heads. I don't remember specifically but I believe what Sony said and the technician reinforced was that the heads had premature wear, ie no warranty. When he told the tech about reusing tapes he said "Yyyyup". So take from that what you will. I think the PD150 had about 300 hours on the heads at the time, should easily have gone 700 and probably much more. Reuse your tapes if you would like but I have never had to replace heads in a camera and I also have never reused a tape.