Runaway Hillbilly Golf Trolley…

Golf trolley heads for the hills…

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Readers of this blog (I know there are millions of you) will recognise this golf trolley and I’m pleased to report that my first repair, the one to the motor, is still working perfectly.  However, the owner of the trolley contacted me with a (funny) problem.  Whilst recently enjoying a round of golf on the local fairway, the trolley decided to, by itself, begin to edge away from the second tee and then with some speed, head off in to the distance, without any operation of the dial switch, situated on the handle.  Whilst this seemed funny at first, I remembered that the motor on this trolley had the kind of torque that, coupled to small gearbox and wheels on a heavy frame, could do some serious damage, left unchecked.

Original photo taken in Aug’17, below.

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FixItWorkshop, Worthing, Aug’17 Hillbilly Compact Golf Trolley

Unlike many modern electric golf trolleys, it doesn’t feature GPS guidance, remote control or amazingly, a dead-man’s switch, which seems like a major safety oversight to me.  I’d have expected either a kill switch or dead-man’s switch* fitted to the handle on a trolley like this as the runaway scenario could never occur due to fail-safe nature of the switch being operated.  With one, the trolley would only run when the operators’ hand was on the handle or cut out when the kill switch is activated, as with the saftety cord mechanism, on a jet ski for example.  Perhaps the Mk2 Hillbilly Compact featured this.

*For example, a dead-man’s switch is usually fitted to something like an electric saw where the operator must old a handle-type switch to make it run.  Once the operator lets go of the handle, the motor automatically fails-safe and cuts-out.

On with the repair.  The trolley features some exposed connectors and cabling and it seemed sensible to check the continuity of the cables running up and down the handle shaft, as repeated trolley folding might have caused a problem with the wiring.  Fortunately, the cabling was OK.

The owner had mentioned that the handle, where the speed control switch is located, had got wet in the past, which made my alarm bells ring.

Opening up the handle, which only required a basic tool kit, revealed evidence of water damage and corrosion to the speed control terminals.  Luckily the owner of the trolley had stocked up on spare switches!

Removing the existing switch revealed intermittent continuity and varying amounts of resistance, which was not good.  A fault most likely to have been caused by water ingress or excessive shock.  The owner had supplied two ‘new old stock’ (NOS) switches.  Which one to fit?

From time to time, it’s downright sensible to either fit NOS or second-parts as they’re usually cost-effective and are more likely to fit over pattern parts.  But time can also affect apparently shiny parts.  This was a case in point.  I knew that the switch should vary resistance from open circuit to 10KOhms in either direction from COMM.  The old one didn’t and one of the ‘new’ parts only went to 2KOhms, so was not in specification.  Luckily, the remaining NOS switch worked fine and once refitted, and the handle reassembled, the golf trolley was ready to make the job of carrying clubs easier, once again.

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FixItWorkshop, Feb’18, Hillbilly Compact speed control switch, new and old- test NOS parts before fitting.

Cost of replacement trolley:  ££££ Cost of repair; £10 plus time.  Moral of the story; don’t assume NOS parts will work.  Test them first.

 

Nearly flaming 1986 Yamaha XT600 Ténéré

Beloved Yamaha XT600 Ténéré nearly goes up in smoke.

I’ve had my beloved Yamaha XT600 Ténéré for about 8 years and have deliberately kept it away from these pages as I’m always doing something to it.  It could have its own website with the amount of time, not to mention money and effort I’ve spent on it.

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FixItWorkshop, Jan’18, Yamaha XT600 Ténéré.

This story is note-worthy as it’s a lesson for me and others who ride and maintain old bikes!

I don’t use the bike that much at the moment, but I always keep it ready for the road, just in case I get a chance to take it out.  Whilst doing a few checks recently, I decided to fire it up and get the oil pumping around the engine, so that things don’t seize up.

The tank was pretty full (over 20 litres) and upon opening up the manual fuel valves, giving it a bit of choke, the engine fired-up on the second crank.  It sounded quite sweet.

However, after about 30 seconds, I heard ‘running liquid’ before smelling the intense scent of super unleaded.  Looking down, I was standing in about 2 pints of fuel, on the wooden shed floor with a hot exhaust casually burning the fuel that was dripping on to it.  Nasty.

I won’t repeat what I said, but suffice to say, I hit the bikes’ kill switch virtually instantly.  I shut the flowing fuel off and wheeled the bike out in to the open air.

After several cups of tea, I found the cause of the problem.  The small fuel feed pipe which runs from the float chamber to the main jet on the carburettor had failed causing the leak.

When I bought the bike, I thought I’d changed all the fuel lines, but I’d missed one, quite an important one as it turned out.  It goes to show that even enthusiastic mechanics make mistakes.

The cost of the repair was £1 for a new piece of fuel hose, but the point of this story is:  If you have any petrol-powered things, especially old motorbikes; don’t run them in an enclosed wooden space.  Always run them outside.

Outdoor LED porch light on the blink

Outside light on the blink

A couple of years ago, I made a light for our porch.  I wanted to ‘back-light’ the area under the porch with a subtle glow, when coming back home in the dark, handy when trying to find the front door keys.  I used a clear section of hose pipe, several clips and a strip of LED tape, commonly available from lighting suppliers.  I used a standard 12V power supply unit (PSU) from an electrical wholesalers’ and controlled the whole thing with a neat little PIR motion/ day-night detector.  It all worked quite well until the other day.

Whilst walking past the PIR detector the light came on in the usual way, but there was a strange ‘arcing’ noise, coming from the inspection panel, behind which I’d mounted the PSU.  The PSU seemed a sensible place to begin investigation.

It’s really irritating when manufacturers’ chose to make it so that a casing for something does not come apart, without breaking in to it.  This PSU was made this way and to gain access, I had to carefully lever the two halves of the glued casing apart with a screwdriver, breaking the glue holding it together.  It wasn’t working anyway, so what did it matter.

Looking at the printed circuit board (PCB) within the plastic casing revealed that the mains feed, presented as an IEC Kettle type connector in this case, had a ‘dry-joint’ and had begun arcing (small sparks) which left unchecked, would have caused permanent damage to the PSU.

With a small clean-up of the affected joint and a little soldering, the PSU was as good as new.  Sadly, the casing won’t be the same again, but as it’s hidden out of sight, I decided that a good wrapping of electrical tape around the two halves of the PSU casing was all that was needed.

Cost of a replacement PSU:  Circa £15.  Cost of repair: A bit of solder and my time.

Vedette Wall Clock ne marche pas

A little repair on a French wall clock

This lovely wall clock had been running perfectly fine until a friend of mine decided to move it temporarily from the wall, during a recent bout of home decorating.  Now, I’m no expert on French wall clocks, but we think this one is circa 1920s or 30s, but either way, it’s a lovely thing to have in the house.  This one is also fitted with Westminster chimes, so one assumes it was made for the English market as an export item, all those years ago.

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FixItWorkshop, Jan’18, Vedette Wall Clock (French)

Once the paint had dried, the owner decided to re-fit the clock to its hook on the wall, but it simply didn’t run, even when fully wound-up.  Strange, what had happened?

Having a quick look at the front of the clock revealed nothing much.  The pendulum was where it should be and appeared to swing freely, as a pendulum should, but there was a slightly strange ‘double-click’ tick-tock, indicating something wasn’t right.  Clocks of this type should emit a definite even tick – tock -tick-tock.  This one wasn’t. Hmm.

Before going to see the clock, I had already decided that the small spring that suspends the pendulum could have been broken, so I packed a few spares I happened to have, just in case.  Opening up the mechanism revealed that the spring was actually intact, not bent or warped and therefore perfectly serviceable.  It was fairly obvious almost immediately that the small clasp which secures the pendulum to the escapement lever was bent and the probably cause of the problem.  All that was needed was a small amount of tinker-time to fix that with a small pair of pliers.  However, that wasn’t the end of the story.  Having undergone a ham-fisted removal from the wall, the escapement pendulum lever was now in a slightly different position and some more fettling was required to get the clock back ‘in-beat’, a common requirement on this mechanism type and often the reason why a clock won’t run, even when fully wound.

As the clock mechanism was out of the main casing (see photo) I decided to prop-up the mechanism on two tins of beans to allow the pendulum to hang over the side of a level table.  This allowed me to access to the clock’s mechanism and hear what was going on clearly.  A slight adjustment on the main pendulum lever to the right on this mechanism and the clock was back ‘in beat’, keeping good time.

After giving the case a general clean up and polish, I refitted the clock mechanism back inside it and hung the whole thing back on its hook, back where it belonged, on the wall.

Cost of a replacement: Sky’s the limit. Cost of repair; 1 cup of tea and 1 chocolate digestive.

A fan with a wobbly tale…

A fan with a wobbly tale…

Now, before I start the story, I have a confession.  I technically stole this room fan.  I didn’t pay for it, I just took it.

Just before Christmas 2017, I noticed that a room fan had been dumped in the small carpark at the end of my road.  At first, I assumed that it was being left on a temporary basis, ready to be taken to the tip in a responsible manner, but as the days and weeks rolled on, it became clear that someone had carelessly left it there to turn to rust, which seemed a shame.

I did the only responsible thing; pick it up off the ground and take it back to the workshop in broad daylight.

Once I’d allowed it to dry out, I plugged it in and guess what, it powered up and ran on all three speeds without an issue.  Its operation was very smooth and quiet.  On closer inspection, it didn’t seem that old to me.  How strange.

The major problem with the fan was that it didn’t stand up properly, in fact it would fall over easily.  The fan’s base stand was a simple cross-section of metal feet, supporting the main pole which holds the fan itself.  The whole assembly was loose and being held together with masking tape, which was far from ideal.

Once I’d removed half-a-roll of masking tape from the stand, it revealed that one of the screws that holds the main pole to the stand was missing and the remaining three were loose.  Could it really be that simple?

Once I’d straightened the slightly bent metal work in the vice, replaced the missing screw with one I already had in my nut and bolt pots, tightened the rest up, the stand performed as a stand once again and the whole thing worked without wobbling in a drunken manner.

Now, this probably wasn’t an expensive item.  It’s not the finest example of good design or build quality.  But it struck me then that the otherwise fine fan had been condemned on the one missing screw and the owners’ simple lack of screw driver aptitude.  Crazy.  I find it very sad that something with plenty of life left in it ends up dumped in a car park over one missing screw.  Some people have a very disposable and wasteful view of everyday items.

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FixItWorkshop, Jan’18, fan repaired.

I did repaint some of the rusty metal work after these photos were taken.

Cost of a new fan:  £15 to over £100.  Cost of repair; 5p.

 

 

G.E.T. Dehumidifier with damp issues…

GET dehumidifier with damp issues…

Over a cuppa, my mother in law mentioned that she was chucking out a dehumidifer this weekend and had already replaced it.  This was a shock to me since it hadn’t started it’s journey to Worthing tip via my shed yet.  Time to intervene.

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FixItWorkshop, Jan’18, GET Dehumidifier repair.

Aparently it had overflowed water all over the floor and had cut out and not restarted.  It had probably been left to its own devices in their cellar, totally neglected in the run up to its demise.

Before worrying my toolbox, I usually plug things in and press buttons to see what happens.  When connecting this dehumidifier to the mains, it fired-up and seemed to run perfectly.  Strange.

Looking at the device in more detail revealed three tell-tale LED lights (cooling, empty the tank and running).  The tank was removable from the front and featured a small float operated level which married up to a small microswitch.  The idea being that when the water rose to the top, the switch would be activated by the float and the machine would cut out safely, all being well.

The lever mechanism on the float seemed to be stiff and all that was required to restore service was a good clean with a brush and Fairy liquid and some silicone spray, once dried.

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FixItWorkshop, Jan’18, GET Dehumidifier repair, microswitch.

While giving the unit a general inspection, I noticed dirt in the units’ grille.  Fortunately, the grille had a removable filter which had clearly never been cleaned, so in effect had been chocking the dehumidifer in normal operation.  Bad news.

Piecing the evidence together in my mind surrounding the causes of failure, I came up with the following theory.  The float had failed, causing the unit to leak.  The unit had then run hot, probably for a while and had probably tripped a thermal protection fuse.  I have no evidence for the latter idea as I never opened up the unit fully, but the theory fits the sequence of events.

In any case, the dehimidifier now switches on and switches off when full and doesn’t seem to run hot.  I was pleased with that.  I wasn’t so pleased that my in-laws wanted the unit back.

Cost of replacement: Circa £100.  Cost of repair; cleaning stuff.

 

Elna SP sewing machine… Totally stitched up.

A Sewing Machine Repair…

On first impressions, this machine didn’t have a lot going for it.  It had been stored in a garden shed, never the best place to store a sewing machine, it was dirty, neglected and broken.  However, the weight of it indicated that this was a quality item and worth investigating.

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FixItWorkshop, Nov’17, Elna SP Sewing Machine in case.

This machine comes from a different time in manufacturing where the focus was on quality rather than on price-point in the market and as a result, it’s made to outlive most people.  In fact, many electric sewing machines made by Elna, Singer, Toyota, Janome, Brother and so on, built until the 1980s, are items of sheer mechanical excellence inside and should be cherished.  Anyway, on with the problem and repair.

The owner had stashed the machine away many years ago and as a result, it had seized.  Details of the fault were scant, I was just told that it didn’t work!  Upon powering it up and operating the foot pedal, the hand wheel turned slightly before making a horrible mains AC hum.  It was time to un-plug, rapidly.

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FixItWorkshop, Nov’17, Elna SP.

There are exposed oiling points on the Elna SP, a nice maintenance touch, but clearly these hadn’t been used in many a year.  Opening up the machine’s lid on top of the motor and bobbin transmission cover below revealed a lot of dirt and neglect which I first cleaned and then oiled lightly with special oil, in to all the moving parts.  Automotive brake cleaner was used to remove old dirt and grease from the needle area and gears.  New grease was then applied to the parts that needed it and more oil to other ‘metal on metal’ parts.  The trick here is to not apply so much oil that it ends up on the fabric being stitched.

Once the machine was running smoothly again, I noticed that the bobbin shuttle wasn’t turning, not even a little bit.  Not ideal.  Time to delve a little deeper and on this machine, it meant complete disassembly of the bobbin shuttle assembly, which then revealed a stripped worm-drive hook gear (part 403030).  This seems to be a fairly common issue on these machines as they get older.

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FixItWorkshop, Nov’17, part 403030 for Elna SP.

Obtaining a new hook gear was quite easy via eBay; BSK (Bedford Sewing Knitting Machines) supplied the part for a reasonable £15.99 including P&P within 24 hours.  Once fitted, it was a case of fine-tuning the bobbin/ hook timing to suit the needle.  It’s a similar principle to valve and ignition timing on a petrol engine car, a process that will be familiar to anyone who’s ever done any spannering on an old Mini or Escort for example.

With the timing complete, a few tests using old material revealed that the machine was working once again with no missed stitches.  I gave the machine a final polish with car wax before handing it back to the owner for my own satisfaction.

 

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FixItWorkshop, Nov’17, Elna SP Sewing machine repaired.

Thanks also to More Sewing in Worthing, West Sussex for their advice on machine oil.  www.moresewing.co.uk.

Cost of a new machine (of this quality): £500 plus.  Cost of repair:  £15.99, plus time, plus a little oil and patience.