wooden gear clocks uk - egloospds23.egloos.com/pds/201201/20/64/build_manual.pdfwooden gear clocks...

Wooden Gear Clocks UK 316 Pickering Road, Hull, East Yorkshire, UK Tel 01482 509277

http://wooden-gear-clocks.co.uk/

Build Manual for “Clockerel” Electromechanical Wooden Geared Clock

Thank you for purchasing the “Clockerel” electromechanical clock kit from Wooden Gear Clocks UK. We called it the “Clockerel” as it resembles a flightless bird of some kind, probably, but not exclusively, a Clockerel. The aim of this manual is to make the construction of this kit enjoyable, safe and rewarding. The clock is powered by 4 x D cell Alkaline batteries. SAFETY Always read and digest any safety instructions that came with your tools. Wooden Gear Clocks do not accept any responsibility for any injuries incurred during the construction of this clock. TOOLS The tools required to carry out this build are as follows: A bench vice (fitted with jaw protectors) is desirable but not essential. An electric drill, preferably battery operated. A square file, approximately ¼” and a flat file approximately 15mm wide. A sharp chisel approximately 12mm wide. Soldering iron, solder etc. Rapid setting epoxy resin e.g. Araldite PVA wood glue Sanding Block Shellac, color up to the customer. Plastic “Scotchbrite” washingup pad. 1-2 required. Aluminium oxide abrasive paper. Grade 80, 120 and 180.

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Aerosol can of automotive clear spray lacquer. Jig as drawing Clockerel-0016 8mm drill bit or countersink bit Flat 300mm steel rule SKILLS A knowledge of basic wood finishing techniques and the ability to read drawings. Basic soldering skills are also required, but not essential as you could always get someone with the skills to perform these tasks. Six soldered joints are required to complete the clock. These instructions are to be read in conjunction with drawings Clockerel-0001 to 0017. PARTS Please check all parts against the parts list (BOM). If any parts are missing then please contact us immediately. INSTRUCTIONS 1. Drawing Clockerel-0001

Carefully remove the cutter radii from the frame hole in item 2 with a sharp chisel or square file. This is the most difficult part of the build and will reflect in quality of the finished clock. When these corners are square trial fit the frame into the hole. If it is too tight then carefully sand the frame where it fits into the hole. It is easier to make this part smaller than make the hole larger. Only a small amount of sanding should be required. Repeat this process with the switch hole and trial fit the switch. Apply PVA adhesive to one of the mating surfaces and press together with part 1. Place the base on a flat surface with a heavy object to sandwich the assembly. Ensure that the two parts are correctly aligned around the edges. Leave for 4 hours and then finish as per preparation of the MDF parts.

2. Preparation of parts

MDF parts: It is very important that the edges of these parts are well sanded to a smooth finish. The finish of the edges will reflect in the overall appearance of the clock. All machining marks must be removed with 80 grade abrasive paper. Only sand in the direction of the edge, NOT across it. Sanding across the edge could break away the veneer as well as not giving a good finish. Work your way down to the 180 grade paper and finish with a Scotchbrite pad. The edges should now be smooth with an even texture. The veneered side can be sanded with just the 180 grade abrasive paper and Scotchbrite, working in the direction of the grain. Only a light sanding is required. After preparation apply shellac to all exterior surfaces and sand with a Scotchbrite when dry, paying particular attention to the edges. Repeat this process until the edges are smooth with an even dark texture (approximately 3 times).

Plywood parts:

The faces should be carefully sanded with 180 grade abrasive paper wrapped around a sanding block. Lay the parts on a flat surface and carefully sand the faces in the direction of the grain. The faces can also be sanded by gluing a sheet of 180 grade to a flat surface and rubbing the parts on this. Wrap a small amount of 180 grade paper into the size of a flattened cigarette to do the inner edges and teeth. Only sand the teeth to remove ragged edges. DO NOT sand too much as the profile of the teeth may be effected. The faces of the parts may be treated with shellac as above if required.

3. Drawing Clockerel-0002

Countersink the 4 holes in the base cover (9) and screw to the base using the 4 screws (10). The holes in the base (3) may need pilot drilling in order to insert the screws easily. Attach the 4 felt pads (11) to

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the cover as shown. Insert the frame (2) into the rectangular hole in the base paying attention to the dimensions shown on the drawing. The tip should measure between 250 and 254mm from the base. The frame should be glued with a small amount of adhesive in the bottom of the hole if it is not a tight fit.

The Frame assembly can then be lacquered to the required finish. Roll small pieces of card and insert into the bearing and face holes to prevent a build up of lacquer inside the holes. When the desired finish has been achieved the bearings can be fitted into the holes as shown in section C-C. The bearings should be pressed partly into the holes using finger pressure. If they are too tight then lightly sand the inside of the holes until the desired fit is achieved. Push the bearings fully home with the flat side of a 25mm wide steel rule or similar. This ensures that the bearings are square and flush with the face of the frame.

4. Clockerel-0003/0004

The electrical components should now be installed. Remove the base cover and hold the frame inverted between your legs or place inverted on the edge of a table. Cut 1 piece of red wire 260mm long and 1 piece 160mm long. Solder these to the switch terminals and install into the frame with the wires passing through the hole. Solder the longer wire to the POSITIVE terminal of the battery box. Cut 1 piece of black wire 140mm long and solder to the NEGATIVE terminal of the battery box. Insert the battery box into the frame ensuring that the terminals are facing towards the switch side of the clock. Cut 1 piece of red wire 120mm long and 1 piece of black wire 120mm long. Solder the red wire to the longer terminal of the LED and the black wire to the shorter terminal. Push a piece of the heat shrink material over one of the terminals to prevent a short circuit between the terminals. Shrink this on with a cigarette lighter, being careful not to burn it. Insert the LED into the hole in the base of the clock. Push the LED to the mid point of the hole. If you require the LED to be visible then push it through the hole. Place the coil into the frame recess paying attention to the orientation shown in drawing Clockerel-0004. Burn or sand the lacquer from the coil terminals and connect these to the 2 center terminals of the circuit board. Connect the LED wires as shown in the wiring schematic. Connect the black wire from the battery box and the red wire from the switch to the circuit board as shown. Be careful to get these the correct way round. The circuit board is not polarity protected due to resistance issues. Incorrect connection would damage the board. Insert the circuit board into the base as shown. Roll up some tissue paper and place above the coil to keep this in position at the bottom of the recess once the cover has been replaced. Masking tape may be used to keep the wires in the wiring grooves during installation.

5. Clockerel-0009 / 30 tooth wheel assembly

Cut part 1 to length from the short piece of 3mm diameter brass rod, not the long length. Make this part 46mm long as tolerances in wood thicknesses make this length difficult to define exactly. Using the one bearing that is not fitted as a gauge, trial fit the rod into the bearing. It should be an easy sliding fit into the inner race of the bearing. It may not be at this stage so place it into the battery drill and sand slightly with 180 grade abrasive paper until a sliding fit is acquired. Turn it and repeat the other end being careful not to re sand the section already done. The rod should now slide easily through the bearing but not be slack. Trial fit the shaft into the bearings in the frame. If it does not slide easily through both bearings then one or both are misaligned. Investigate fit. Inset the shaft 1 through the 3mm hole in the jig allowing 6mm to protrude (use wheel to measure this). Place a small amount of epoxy inside the hole of part 2 and not on the shaft. This ensures that oozing adhesive does not cause the part to stick to the jig. Place the wheel over the shaft ensuring that the best side faces towards the front of the clock. Remove the part from the jig by pushing on the rod from beneath and not by pulling the wheel. Remove it when the remaining mixed adhesive has dried. Now place a small amount of adhesive on the shaft adjacent to and on part 2. Slide part 3 down the shaft and into position. Allow to dry. This method of assembly ensures that adhesive does not get on the shaft. When the assembly is fully dried, slide part 3 down the shaft. Place a small amount of epoxy onto the mating face of part 4 being careful not to get any into the hole. Push part 4 fully onto the shaft and slide

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part 3 back up to adhere to it. Leave until remaining epoxy mix has almost dried and then carefully withdraw from the shaft without misaligning the parts. Allow it to dry thoroughly. Remove any epoxy from the end of the shaft which may have leaked out. The part can now be fitted to the clock temporarily with the 2 washers (5). The part should have approximately 1mm of end float (side to side movement) when assembled in the frame. File the end of the shaft until the desired end float is achieved. Ensure that part 4 is fitted fully onto the shaft. The part should spin freely.

6. Clockerel-0008 / 60 tooth wheel assembly Cut part 1 to length from the remaining 3mm diameter brass rod. Make this part 70mm long.

Repeat the basic assembly instructions as above for the 30 tooth wheel assembly.

7. Clockerel-0011 / 64 tooth wheel assembly

Cut part 1 to length from the remaining 3mm diameter brass rod. Make this part 112mm long. Repeat the instructions as above for the 30 tooth wheel assembly and the 60 tooth wheel assembly. This assembly cannot be adjusted for end float until the final assembly.

8. Clockerel-0006 / Ratchet wheel assembly

Cut part 1 to length from the remaining 3mm diameter brass rod. Make this part 51mm long. Repeat the sanding instructions on the rod as above. Place some epoxy resin inside the hole of part 2 and a small mount on the mating face. Position part 2 on the shaft as shown. Slide part 3 down the shaft and into position whilst holding part 1 so that it does not push off. Allow the sub assembly to dry. Lay part 4 on the assembly jig, paying attention to the orientation of the ratchet. The wheel should drive in a clockwise direction as shown. Place a small amount of epoxy on the mating face of part 3 and a small amount on the shaft adjacent to the mating face (no more than 6mm along the shaft). Push the shaft through the hole in part 4 and through the hole in the jig until fully home. Leave to dry. Remove from the jig as previously described and place a small amount of epoxy onto the mating face of part 4. Push part 3 into position until full home. The part can now be fitted to the clock temporarily with the 2 washers (5) and part 6. The part should have approximately 1mm of end float (side to side movement) when assembled. File the end of the shaft until the desired end float is achieved. Ensure that part 6 is fitted fully onto the shaft. The part should spin freely.

9. Clockerel-0005 / Pendulum pawl assembly

Cut part 1 to length from the remaining 3mm diameter brass rod. Make this part 56mm long. Repeat the sanding instructions on the rod as above. Place some epoxy resin inside the hole of part 2. Position part 2 on the shaft as shown and allow it to dry. Clean away any epoxy that has oozed from the hole with a sharp knife before it has full dried. Lay part 3 on the assembly jig, paying attention to the orientation. Place a small amount of epoxy on the mating face of part 2 and a small amount on the shaft adjacent to the mating face (no more than 6mm along the shaft). Push the shaft through the hole in part 3 and through the hole in the jig until fully home. Leave the sub assembly to dry. Lay part 5 onto a flat surface viewed as shown in the bottom left view. Place a very small amount of epoxy on the inside of the leading edge of the bearing hole. Push the bearing 8 squarely into place using the flat side of a 25mm wide steel rule or similar until flush with the front surface of the part. Remove the sub assembly from the jig. Cut part 10 to length. Make this part 16mm long. Place a small amount of epoxy inside the hole in part 3 and insert the pin 10 from the back to ensure no epoxy gets onto the shaft. Leave the part to dry. Place a washer over the pin 10 followed by part 4 as shown. Secure the parts in place with part 11. place a washer over the shaft 1 followed by part 4 as shown. A further 4 washers are placed along the shaft followed by part 6. Part 5 should pivot freely at this point as the washers should ensure clearance between it and the adjacent parts. If it does not pivot freely check the bearing 8 for freedom of rotation.

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The part can now be fitted to the temporarily with the 2 washers (9) and the part 7. Check for 1mm end float and adjust shaft length as necessary.

10. Clockerel-0010 / Hour hand assembly

Cut part 1 to length. Make this part 54mm long. Clean the inside of the tube where it has been cut to remove any rough edges. Insert The tube into the assembly jig allowing approximately 18mm to protrude. Slide part 4 over the tube until flush with the jig ensuring the best side faces the front of the clock. Approximately 12mm of tube should now be protruding from the gear wheel 4. Place a small amount of epoxy on the tube adjacent to the gear wheel. Gently tap the tube into the gear wheel until 6.5mm protrudes. Allow the sub assembly to dry. Remove the sub assembly from the jig as described earlier. Place a small amount of epoxy onto the mating face of part 4. Slide part 3 along the tube until flush. Repeat this process for the remaining 4 spacers and allow it to dry. When dry position the hour hand 2 and the last spacer 3 onto the tube as shown. The hour hand should be firm on the shaft without being too difficult to turn. If the tube protrudes beyond part 3 then file it down until it is as shown. Set the assembly aside.

11. Clockerel-0007 / Pendulum shaft assembly

Cut part 1 to length from the 1/8” wooden dowel. Make this part 270mm long initially. Screw item 4 onto one end approximately 30mm as shown. Screw item 2 onto the shaft as shown about 4 turns. Place the magnet, item 3 onto item 2 as shown. Set the assembly aside.

12. Clockerel-0013 / Face assembly

Cut the 9mm dowel into 2 lengths each 62mm long (2). Sand each end until it is a sliding fit into the frame and the face. Glue the dowels into the face as shown.

Set the assembly aside. 13. Clockerel-0014 / Clockerel assembly exploded.

Remove all parts from the clock which may have been temporarily assembled. Insert 4 x D cell batteries into the clock and switch off. Ensure Alkaline batteries are used and that they are fitted correctly (Polarity). As stated earlier the clock has no polarity protection as this would result in a reduced battery life. Insert the ratchet wheel assembly 1 into the bearings as shown. Ensure that the 2 washers are inserted either side on the bearings. Insert the 60 tooth wheel assembly 2 into the bearings as shown. Ensure that the washers are inserted either side of the bearings. Insert the 30 tooth wheel assembly 4 into the bearings as shown. Ensure that the washers are inserted either side of the bearings. Insert the 64 tooth wheel assembly 3 into the bearings as far as the second bearing. Ensure that the washer was inserted on the shaft before this operation. Position the hour hand assembly 5 into position under the 60 tooth wheel. Slide the 64 tooth wheel the remainder of the way and into the hour hand assembly. The face assembly 8 can now be fitted. The face should have a standoff from the 60 tooth wheel of approximately 3mm as shown in Clockerel-0015. Reduce the length of the dowels if necessary. The minute hand can now be fitted as shown. The hour hand assembly should have approximately 1mm of end float on the shaft. Adjust the length of the 64 tooth wheel shaft if necessary. Insert the pendulum assembly 6 into the bearings as shown. Be careful to engage the drive pawl and the non return pawl onto the ratchet wheel. Ensure that the washers are inserted either side of the bearings and that there is approximately 1mm of end float with the pendulum mount fitted.

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Glue the pendulum shaft into the pendulum mount so that there is approximately 2mm of clearance between the magnet and the base. Adjust the shaft length as necessary. Allow it to dry.

14. Clockerel-0018 / Ratchet setup detail.

Adjust the pawls as per the drawing by holding the drive pawl lever in one hand and turning the pendulum mount. Switch on the clock and give the pendulum a gentle push. Look down at the LED. This should be flashing each time the magnet passes the centre of the coil. If it seems to be flashing erratically then turn the magnet around. The clock will probably swing too far at this point. The ideal magnitude of swing will just allow the drive pawl to engage and the non return pawl to just engage. The pendulum should swing to about the edge of the base. To reduce the swing, screw the magnet holder further onto the shaft so that the distance between the magnet and coil increases. The shaft may need reducing in length. When the clock appears to be running ok then set the hour. If the clock runs fast then screw the bob weight down the shaft, effectively lengthening the pendulum. If the clock runs slow then screw the bob weight up the shaft, effectively shortening the pendulum. This process may require minimal adjustment as the clock becomes more accurate.

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THIRD ANGLE PROJECTION

2

1

Prior to glueing,remove cutter radii from the frame hole with a sharp chisel or file. This is the most difficult part of the build. Ensure this is done neatly to give a snug fit for the frame.If you do not feel confident doing this then get a competent person to do it for you.

Prior to glueing, remove cutter radii from the switch hole. This hole is not as criticalas the other as switch flange coversthe edge of the hole.

Apply pva adhesiveto mating surface.

Triangles denote that this part is glued to shaft and the adjacent part.Pentagon denotes that this part is glued to adjacent part only so that assembly can be removed.Circles denote an interferance or loose fit.

ITEM NO. PART NUMBER DESCRIPTION QTY.1 Base bottom 12 Base top 1

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UNLESS OTHERWISE SPECIFIED:DIMENSIONS ARE IN MILLIMETERSSURFACE FINISH:TOLERANCES: LINEAR: ANGULAR:

FINISH: DEBUR AND BREAK SHARP EDGES

NAME SIGNATURE DATE

MATERIAL:

TITLE:

DWG NO.

SCALE:1:5 SHEET 1 OF 1

A4

WEIGHT:

Wooden Gear Clocks316 Pickering Road, Hull, East Yorkshire, HU4 7AD.Tel. 01482 509277 wooden-gear-clocks.co.uk

Base assembly

MDF Clockerel-0001


252 -2+2

B

B

C

C

SECTION B-B SCALE 1 : 2

3

2Ensure that the holeis clean at the bottomto allow the frame toseat squarely in thehole

All bearing fits the same

9

7

SECTION C-C SCALE 1 : 2

2

11

1011

NotesThe frame may be glued into the baseif the fit appears to be a bit loose. Carefulfitting should give a tight fit that does not requireadhesive.The frame should be finished and laquered beforefitting the bearings. Laquer on the bearings would effect the clock operation.


ITEM NO. PART NUMBER DESCRIPTION QTY.

1 Bearing 623zz 102 Frame 13 Base assembly See Dwg Cockerel-0001 17 Switch 19 Base Cover 1

10 Screws 3.5x20 411 Self adhesive felt pad 4

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NAME SIGNATURE DATE

MATERIAL:

TITLE:

DWG NO.


A4

WEIGHT:


Clockerel-0002

Frame assembly


Circuit board

LED

Coil

Switch

Battery holder

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NAME SIGNATURE DATE

MATERIAL:

TITLE:

DWG NO.


A4

WEIGHT:


Wiring schematic

Clockerel-0003


B B

65 7 8

4

2

3

Wiring groove

Ensure battery holder terminals are positioned at wiring groove side.


Circuit board is positioned components downwards.Ensure that terminal strip is next to wiring groove when inthe inverted position.

ITEM NO. PART NUMBER DESCRIPTION QTY.2 frame 13 Base assembly 14 Battery holder 15 Coil 16 Simplified circuit

board 1

7 Switch 18 LED 1

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NAME SIGNATURE DATE

MATERIAL:

TITLE:

DWG NO.


A4

WEIGHT:


Positioning of electronic components

Clockerel-0004


G G4

3 4

5

2

7

SECTION G-G SCALE 1 : 1 7

1

3 2

4 11

10

9


9

DETAIL J SCALE 2 : 1

8

9

5

9

9

6


1 Pendulum shaft Approximatel 54mm long x 3 12 6mm thk spacer 3mm hole blind 13 drive pawl lever 14 drive pawl 15 non return pawl 16 6mm thk spacer 3mm hole 17 Pendulum mount 18 Bearing 623zz 19 M3 washer 810 Pawl pin 111 Pawl pin retainer 1

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NAME SIGNATURE DATE

MATERIAL:

TITLE:

DWG NO.


A4

WEIGHT:


Pendulum pawl assembly

Clockerel-0005


B

B

Triangles denote that this part is glued to shaft and the adjacent part.Pentagon denotes that this part is glued to adjacent part only so that the sub assembly can be removed.Circles denote an interferance or loose fit.


21

4

5

5

3

3 6

ITEM NO. PART NUMBER DESCRIPTION QTY.1 Ratchet wheel shaft Approximately 49mm long x 3 12 8 tooth wheel 13 6mm thk spacer 3mm

hole 2

4 Ratchet wheel 15 M3 washer 26 6mm thk spacer 3mm

hole blind 1

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NAME SIGNATURE DATE

MATERIAL:

TITLE:

DWG NO.


A4

WEIGHT:

Wooden Gear Clocks316 Pickering Road, Hull, East Yorkshire, HU4 7AD.Tel. 01482 509277

Ratchet wheel assembly

Clockerel-0006


E

E

DETAIL B SCALE 1 : 1

SECTION E-E SCALE 1 : 1

1

4

3

2

ITEM NO. PART NUMBER DESCRIPTION QTY.1 Bob weight shaft Approximately 270mm long x

3.2mm wooden dowel 1

2 Nut insert 13 Magnet 14 Bob weight 1

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NAME SIGNATURE DATE

MATERIAL:

TITLE:

DWG NO.


A4

WEIGHT:


Pendulum shaft assembly

Various Clockerel-0007


B

B


SECTION B-B SCALE 1 : 1.5

2

3 3 3

3 3 3

4

5

51

ITEM NO. PART NUMBER DESCRIPTION QTY.1 60 toth wheel shaft Approximately 68mmlong x 3 12 60 tooth wheel 13 6mm thk spacer 3mm hole 64 8 tooth wheel 15 M3 washer 2

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NAME SIGNATURE DATE

MATERIAL:

TITLE:

DWG NO.


A4

WEIGHT:


60 tooth wheel assembly

Clockerel-0008


B

B

Triangles denote that this part is glued to shaft and the adjacent part.Pentagon denotes that this part is glued to adjacent part only so that sub assembly can be removed.Circles denote an interferance or loose fit.

2

4

SECTION B-B

4 3 5

1 5 3

2

ITEM NO. PART NUMBER DESCRIPTION QTY.1 30 tooth wheel shaft Approximately 44mm long x 3 12 30 tooth wheel 13 6mm thk spacer 3mm

hole 2

4 8 tooth wheel 15 M3 washer 2

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NAME SIGNATURE DATE

MATERIAL:

TITLE:

DWG NO.


A4

WEIGHT:



Clockerel-0009


B

B

42

3

6.50


2

3

3 3 3

3 3

4

1

Triangles denote that this part is glued to shaft and the adjacent part.Pentagon denotes that this part is glued to adjacent part only so that sub assembly can be removed.Circles denote an interferance or loose fit.

ITEM NO. PART NUMBER DESCRIPTION QTY.1 Cannon tube Approximately 54mm long 12 Hour hand 13 6mm thk spacer 4mm

hole 6

4 32 tooth wheel 1

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NAME SIGNATURE DATE

MATERIAL:

TITLE:

DWG NO.


A4

WEIGHT:


Hour hand assembly

Clockerel-0010


B

B

27

4



2

343 5

751

6

ITEM NO. PART NUMBER DESCRIPTION QTY.1 64 tooth wheel shaft Approximately 110mm long x 3 12 64 tooth wheel 13 6mm thk spacer 3mm

hole 2

4 10 tooth wheel 15 M3 washer 26 6mm thk spacer 3mm

hole blind 1

7 Minute hand 1

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NAME SIGNATURE DATE

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TITLE:

DWG NO.


A4

WEIGHT:


Clockerel-0011



1

2



ITEM NO. PART NUMBER DESCRIPTION QTY.1 Pendulum shaft

assembly See drawing Clockerel-0007 1

2 Pendulum pawl assembly See drawing Clockerel-ooo5 1

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NAME SIGNATURE DATE

MATERIAL:

TITLE:

DWG NO.


A4

WEIGHT:


Pendulum assembly

Clockerel-0012


2

2

1


ITEM NO. PART NUMBER DESCRIPTION QTY.1 Face 12 Dowels Approximately 62mm long x 9

wooden dowel 2

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NAME SIGNATURE DATE

MATERIAL:

TITLE:

DWG NO.


A4

WEIGHT:


Face assembly

Clockerel-0013


8 7

6

6

1 2 3

4

4

1

2

5

3


1 Ratchet wheel assembly DwgClockerel-0006 1

2 60 tooth wheel assembly Dwg Clockerel-0008 1



5 Hour hand assembly Dwg Clockerel-0010 1

6 Pendulum assembly Dwg Clockerel-0012 1

7 Frame assembly Dwg Clockerel-0002 1

8 Face assembly Dwg Clockerel-0013 1

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NAME SIGNATURE DATE

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TITLE:

DWG NO.


A4

WEIGHT:


Clockerel assembly exploded

Clockerel-0014


3

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NAME SIGNATURE DATE

MATERIAL:

TITLE:

DWG NO.


A4

WEIGHT:


Clockerel assembly

Clockerel-0015

Parts ListBOM Table

ITEM NO. PART NUMBER DESCRIPTION QTY.1 Ratchet wheel shaft 12 8 tooth wheel 33 6mm thk spacer 3mm

hole 134 ratchet wheel 15 M3 washer 166 6mm thk spacer 3mm

hole blind 37 60 toth wheel shaft 18 60 tooth wheel 19 64 tooth wheel shaft 110 64 tooth wheel 111 10 tooth wheel 112 Minute hand 113 30 tooth wheel shaft 114 30 tooth wheel 115 Cannon tube 116 Hour hand 117 6mm thk spacer 4mm

hole 618 32 tooth wheel 119 Pendulum shaft 120 drive pawl lever 121 drive pawl 122 non return pawl 123 Pendulum mount 124 Bearing 623zz 1125 Pawl pin 126 Pawl pin retainer 127 Bob weight shaft 128 nut insert 129 Magnet 130 Bob weight 131 frame 132 base bottom 133 base top 134 Battery holder 135 Coil 136 Simplified circuit

board 137 Switch 138 LED 139 Base Cover 140 Screw 3.5 x 20 441 Self adhesive felt pad 442 Face 143 Dowels 2


150

150

19

Drill 2 holes squarely through the board near the centre. One 3mm diameter andone 4mm diameter. These holes must besquare to the board and allow the tube/rodto fit snugly.

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NAME SIGNATURE DATE

MATERIAL:

TITLE:

DWG NO.


A4

WEIGHT:


Gear wheel assembly jig

Clockerel-0016Plywood or MDF


90°

Jig ensures thatgear wheels are squareto the shaft.

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NAME SIGNATURE DATE

MATERIAL:

TITLE:

DWG NO.


A4

WEIGHT:


Clockerel-0017

Assembly jig with 60 tooth wheel



Non return pawl and drive pawl should be set as shown with pendulumat rest. There should be 8 ratchet teethvisible. The drive pawl should beapproximately half way on one tooth.

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NAME SIGNATURE DATE

MATERIAL:

TITLE:

DWG NO.


A4

WEIGHT:


Ratchet setup detail

Clockerel-0018

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