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Converting a 15 Note Music Box to Copper
What you will need:
- 15 Note Music Box
- 30 Note Copper Gear Replacement Kit
- Drill
- Screwdriver
- Vise
- Pliers
- Washers, Nuts, or Something Similarly Circular
Removing the Plastic Gears
- First, unscrew the crankshaft from the music box. This will free the crank gears as well as the comb and neighboring rod.
- From here, you can use the pliers to bend the metal on the smaller gear of the crank assembly. Bend the bracket so that the gear can be removed
- To remove the crankshaft gear, you must remove the snap ring on the opposite side. I have found prying it off with a screwdriver works best. The shaft should now be able to be removed, freeing the gear.
- The last of the plastic gears from the comb and rod can simply be pulled off with your hands.
Prepping the Crank Assembly
This is the only part that should differ from a 30 note gear replacement
- Attach a drill bit to your drill that is slightly larger than the hole diameter where the smaller gear (non-crank gear) was placed, I believe I have been using a 9/64" bit. Use this to widen the hole to accomodate the copper gear.
- Optionally, sand the rough edge caused by drilling the metal.
Reassembling the Crank Assembly
- Place the new copper gear inside the widened hole, and bend the metal back into the position it was in before.
- Insert the crank into the first hole, with the included washer placed after the crank goes through that that hole.
- After the washer, the crank gear is ready to be added. The bump on the gear should be facing away from the knob of the crank.
- Push the crank all the way through the second hole. Hold it there using your hand and use pliers to put the snap ring back on.
Regearing the Comb and Rod
- Take the rod and matching gear, securing it in a vise such that the nuts/washers are pressing against the gear in the vise. Ensure the comb will be able to push through the gear and washer before continuing.
- Tighten the vise until the gear touches the edge of the flat part of the comb's shaft.
- Repeat the process for the other rod.
Reassembling the Movement
- Slide the comb and rod in their respective holes on the box
- Slide the crank assembly onto the comb and rod, and let it fall into the base of the music box. There are small pegs that will help kep it in the right place.
- Screw everything back together.
Troubleshooting
- Lubricating the gears can help greatly, WD-40 works if that's what you have on hand!
- If the gears seem to skip or grind even after lubricating, they may be slightly misaligned. I have found that you can adjust them by working the metal with the pliers to allow the gears to mesh better
What you will need:
- 15 Note Music Box
- 30 Note Copper Gear Replacement Kit
- Drill
- Screwdriver
- Vise
- Pliers
- Washers, Nuts, or Something Similarly Circular
Removing the Plastic Gears
- First, unscrew the crankshaft from the music box. This will free the crank gears as well as the comb and neighboring rod.
- From here, you can use the pliers to bend the metal on the smaller gear of the crank assembly. Bend the bracket so that the gear can be removed
- To remove the crankshaft gear, you must remove the snap ring on the opposite side. I have found prying it off with a screwdriver works best. The shaft should now be able to be removed, freeing the gear.
- The last of the plastic gears from the comb and rod can simply be pulled off with your hands.
Prepping the Crank Assembly
This is the only part that should differ from a 30 note gear replacement
- Attach a drill bit to your drill that is slightly larger than the hole diameter where the smaller gear (non-crank gear) was placed, I believe I have been using a 9/64" bit. Use this to widen the hole to accomodate the copper gear.
- Optionally, sand the rough edge caused by drilling the metal.
Reassembling the Crank Assembly
- Place the new copper gear inside the widened hole, and bend the metal back into the position it was in before.
- Insert the crank into the first hole, with the included washer placed after the crank goes through that that hole.
- After the washer, the crank gear is ready to be added. The bump on the gear should be facing away from the knob of the crank.
- Push the crank all the way through the second hole. Hold it there using your hand and use pliers to put the snap ring back on.
Regearing the Comb and Rod
- Take the rod and matching gear, securing it in a vise such that the nuts/washers are pressing against the gear in the vise. Ensure the comb will be able to push through the gear and washer before continuing.
- Tighten the vise until the gear touches the edge of the flat part of the comb's shaft.
- Repeat the process for the other rod.
Reassembling the Movement
- Slide the comb and rod in their respective holes on the box
- Slide the crank assembly onto the comb and rod, and let it fall into the base of the music box. There are small pegs that will help kep it in the right place.
- Screw everything back together.
Troubleshooting
- Lubricating the gears can help greatly, WD-40 works if that's what you have on hand!
- If the gears seem to skip or grind even after lubricating, they may be slightly misaligned. I have found that you can adjust them by working the metal with the pliers to allow the gears to mesh better