Kondia FV-1 Head disassembly

[Mayhem]

Well I lost half a day yesterday trying to sort out computer issues, so I didn't get as much done as I had hoped.  I also didn't takes as many pictures as I should have, so you will have to use your imagination with some of my descriptions!  Having said that, I seem to have to strip down the work I have done quite frequently to sort out other issues, so there may well be more pics!

First off, I am going to post some pictures of the work Ken and I did on some parts when I visited him last month.  You have seen the issues with these parts and have seen the finished parts in previous posts.  What was missing however, was the actual repair:

The first one is very simple.  Kondia shipped me a part that was missing a hole.  The part was the micrometer screw, which allows the quill travel to be stopped at a specific point.  It also trips the quill feed.  Kondia sent me the drawing, which showed the hole at a specified distance from the end of the screw, parallel to the slot in the other end.  It also specified the diameter and tolerance of the hole.  Now this is a very simple job, which I could have done if my mill was up and running.  However, it wasn't something I was going to attempt on my drill press.  Also, the 6.5mm reamer I needed was waiting for me in the US.

Set up to ensure the hole is parallel tot he slots, as specified on the drawing.
   

Finished.

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The next job was a little more tricky, as the hole in the feed shaft had been drilled off centre and at an angle.  The new hand wheel coupling also had a hole that was drilled at an angle (although very slight).  The main issue was the the detent ball wouldn't work and in fact locked the selector shaft from moving.

Ken and I discussed options and both agreed that the best approach was to weld up the hole in the shaft and drill a new one.  Before we could weld it, we needed to turn up a slug of copper that would slide inside the shaft to prevent the weld penetrating into the bore.  We then headed over to see Jen (Allessence), who very kindly welded up the hole.  Once cool it needed a little persuasion to straighten the shaft and to pull out the slug.  I ran a 7mm reamer through the bore and there was no resistance.  We lined up the collar, marked with a transfer punch and put the hole where it should be and drilled, reamed and countersunk the hole.  We then reamed the bore again and after some fiddling with fitting, the whole assemble worked as it should.

I scribed the position of the hole in the coupling in relation to the shaft.  I've coloured this in photoshop so it is easier to see.
   

The copper plug and retrieval tool.
   

Hole welded and cleaned up.
   

New hole
   

Finished assembly