Repairing a worn rear axle retaining slot

[rfnagel]

ZipZaps Rear Axle Slot Repair
=============================

This is by far the easiest method for repairing the rear axle retaining slot on
a ZipZaps chassis when it has worn to the point of the axle falling out
(causing the gears to mesh improperly). The only drawback to this specific
method is that it is permanent, you can NOT remove the axle once the repair is
complete.

1 - Obtain a fairly thick paperclip.

2 - Cut out a small straight piece of the paperclip a half an inch long using a
    pair of wire cutters or side cutters.

3 - Install the axle of your choice into the worn axle retaining slot, as well
    as it's matching idler gear. Keep in mind, the axle can NOT be removed
    after this repair is completed, so select your axle and idler gear
    carefully.

4 - Slip the piece of the paperclip over the axle in the retaining slot, and
    center it left to right on the chassis.

5 - Apply J-B Weld over the middle quarter of an inch of the paperclip, filling
    the retaining slot flush with the bottom of the chassis.

6 - Allow the J-B Weld to cure (usually overnight).

7 - Paint the JB-Weld and paperclip black, or simply use a permanent black
    magic marker.

Although you can never remove the axle and idler gear ever again, this is
pretty much a permanent repair... the axle will NEVER fall out again, and the
gears will always mesh properly -:)


Rich ¥Weeds¥ Nagel
RichNagel@compuserve.com

[potentiality]

Thanks for the tip. I was thinking about that recently myself. I wonder if something couldn't be jury rigged with plumbers tape that would be removable and reduce friction. Plumbers tape is afterall that substance... forget its name.. the stuff that is slicker than ice.

[rfnagel]

That would be teflon tape. That's a good idea, something like that would work as well, not sure how long the teflon tape would hold up 'tho as it's realatively thin and fragile.

One thing though, in the case of the Zap in the pic in my above post, it's retaining slot was worn way too much to fix it simply with some tape. The curves of the slot (the area that actually clicks/snaps when you pop an axle in a good slot) were completely worn away.

[charliebrown]

rfnagel,

Thanks for the tip! this looks helpful, but....Some people don't want a permanent fix, so instead of welding it, you might just want to tape it in there really nicely. OR you could use rubber cement to hold it in. I don't mean to put down your idea rfnagel, but I just want to help this tip out. Thanks again!

Chuckster...

[Sawblade]

Why not just use elmers glue or something similar? Then you could pull it loose with a little effort.

[frizzen]

Hot glue or a RTV silicone would work just as well as JB Weld or epoxy, and also be removable