Stereo2Go Forum Reader

minty - 2012-02-18 06:48

I have been researching many different repair options for the infamous broken DD center gear. All seen slightly flawed. the problem is due to shrinkage right? Leaving a gap which causes the click click.

My idea is to buy another faulty DD model, and remove the center gear. A small piece could be cut from the plastic outer ring to the same dimensions of the gap left by shrinkage. This piece could then be glued in place to fill the gap. Many gears could be repaired using one spare gear.

Are there any reasons why this repair would not work?

docp - 2012-02-18 07:39

No reason it shouldn't work provided the glue joints are perfect...as you are just adding teeth like any good dentist would

My attempt was to add in either epoxy resin or acrylic resin into the gap and while it sets allow the material to rotate against the opposing gear wheel surface to form the exact size and shape of the teeth. I then trim of any excess/flash and finish off the repair.

I would be a bit worried about the other approach where a) the central metal has to be precisely ground down and b) the outer rim squeezed close together does introduce a bit of residual stress that might result in future cracks/failure

minty - 2012-02-18 07:52

Yes. I have seen the grinding down of the metal center approach. But I doubt the glue joint would last very long. I think my method could work in theory. You would need to use a very sharp blade. Perhaps a razor blade to made a perfectly fitting piece to fit the gap. Worth a try I guess!

bub - 2012-02-18 08:35

Minty this is the method I used to fix my DC2- Adding more teeth from a donor gear. You can find my old thread on it.

My glue joint has held up fine ever since (I used superglue.)

minty - 2012-02-18 09:02

Ah, so it worked eh? And it works perfectly?

docp - 2012-02-18 09:59

I'd recommend precise sanding of the recepient edges and donor edges with 500 grade water emery or finer or a fine nail file/flat file. You might want to start of with a slightly larger donor piece allowing you to sand it down to a precise fit as if using regular low viscosity superglue...if not try thicker Cyanoacrylate : Insta Cure
http://www.hobbylinc.com/htm/hlc/hlc107.htm

happy mending....do post pics

chris69 - 2012-02-18 11:54

Did you just say SHRINKAGE ??? It happens to all of us after a certain age

docp - 2012-02-18 18:26

vintAGE warpAGE and shrinkAGE ...no escaping

bub - 2012-02-18 20:21

It works wonderfully. No thumping/clicking noise at all! I did do some filing and slight reshaping with a heated knife.

The donor gear was from a random Sony WM-2095- a smuch smaller gear but it has the correct teeth size.

index.php?board_oid=193392314111653483&content_oid=193392314111973364

Note that the small piece on top of the repaired gear is a brace to strengthen it, I ground it down later to a much smaller size so that it would not affect the auto-stop mechanism only after the photo was taken.