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17

Weight Shell Assembly

Parts

1 - Weight shell front face (#40)
1 - Weight shell front piece (#38)
3 - Weight shell interior pieces (#39)
1 - Weight shell rear piece (#41)
1 - Weight shell rear face (#20)
1 - Weight shell cover plate (#21)
2 - 1 1/8" dowels
2 - #4 x ½" screws

Assembly Procedure

1) Glue the weight shell pieces together. The pieces are ordered from front to back and oriented as
shown below (40,38,39,39,39,41,20), with the two dowels inserted in the holes on either end of the
shell. Note that the cutouts of the interior pieces have a curved end and a straight end; make sure the
ends are oriented as shown below.

2) After the glue is dry, sand and finish the weight shell and cover (#21).

3) Carefully fill the shell with metal shot.  As the shot nears the rim, jostle the shell back and forth to
settle the metal shot.  Use two #4 x ½" screws to secure the weight shell cover (#21) to the weight
shell.

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Summary of Contents for Crescent

Page 1: ...The Crescent Clock Copyright 2008 Jeffrey A Schierenbeck ...

Page 2: ...ing your own creative touches And through the process of building the clock you will gain an understanding of the principles that govern how a clock works We truly hope you enjoy building your clock Please contact us if there is any way that we can help you with your clockmaking project Tools and Supplies Every part necessary to construct your Crescent clock is included in the kit The following it...

Page 3: ... might benefit from some light sanding especially at the breakaway points where the pieces were attached to the original board Do not sand the mating surfaces of the gear teeth Note that the backsides of some pieces will show residue from the laser cutting operation A light sanding will remove this residue although for nearly all parts this is not necessary because the residue will not be visible ...

Page 4: ... Minute pipe piece 3 9 Rachet 10 Dial 11 11 32 tooth hour gear 12 30 tooth minute gear 13 Set washer 7 14 Lower pendulum shaft 15 Front frame inner piece 16 Minute hand 17 Hour hand 18 Second hand 19 Front frame outer piece 20 Weight shell rear face 21 Weight shell cover plate 22 Weight pulley hook piece 2 23 Weight pulley interior side 2 ...

Page 5: ...llar middle pieces 4 30 Rear frame inner piece 31 Pendulum bob rear piece 32 Pendulum bracket 33 Pillar rear pieces 4 34 Lower pillar middle pieces 3 35 Pendulum support plate 36 Upper pillar slotted middle piece 37 Upper pendulum shaft 38 Weight shell front piece 39 Weight shell interior pieces 3 40 Weight shell front face 41 Weight shell rear piece ...

Page 6: ...spool sides 2 1 4 Diameter Dowels 1 2 Pendulum splice pins 2 3 4 Crutch pin 1 Weight pulley axle 1 1 8 Weight shell rods 2 2 3 4 Pillar rods 4 2 15 16 Winding guide axle 2 1 8 Minute arbor 3 5 8 Escape wheel arbor 2 3 4 Escape lever arbor 2 3 4 Middle wheel arbor 4 5 8 Great wheel arbor Hardware 4 x screws 6 6 x 1 screws 2 Nylon shoulder washers 16 19 braided cord 1 4 20 x 2 hanger bolt 1 4 20 aco...

Page 7: ...r frame However you may still find the stain chart helpful for grouping parts together that should be the same color It is easiest to stain the gears before they are attached to the arbors The other pieces frame weight shell pendulum etc can be stained after the necessary components are glued together The assembly instructions indicate at which time in the process that finish should be applied to ...

Page 8: ...escape lever to rock back and forth along with the pendulum The escape lever alternately stops and then releases one of the wheels in the train called the escape wheel These contacts with the escape lever and the escape wheel teeth generate the tick tock sound of the clock The faster the pendulum moves back and forth the faster the escape wheel and the entire gear train will be allowed to advance ...

Page 9: ... pieces with all three holes aligned After the glue has dried the pulley edges can be sanded and finish applied Next apply a small amount of glue around the rim of the hole in both pulley faces and insert a nylon shoulder washer It might be necessary to either press the washer firmly into place or to tap it into place with a hammer Be sure the washer seats completely into the hole Repeat this proc...

Page 10: ... Then glue together the three pillar middle pieces 34 Next glue together the three pillar rear pieces 26 33 33 After the glue is dry sand the three pillar subassemblies Next glue the three subassemblies together with the two 2 3 4 dowels inserted through the pillar making certain that the pieces are oriented as shown below The dowels should protrude equally approximately 1 4 from both faces Verify...

Page 11: ... pillar pieces in the order shown below from front to rear 26 26 29 29 36 29 29 26 33 33 with the two 2 3 4 dowels inserted through the pillar Dowels should protrude equally approximately 1 4 from both faces 2 After the glue has dried sand this completed upper pillar 3 Attach the pendulum support plate 35 to the upper pillar with a 4 x screw centering it in the recess The slot in the center pillar...

Page 12: ...r pillar assembled previously Lower pillar assembled previously Assembly Procedure 1 Glue together front frame pieces 15 19 Glue together the rear frame pieces 25 30 Make certain that the pieces are oriented as shown below and that the holes are aligned Clamp to a flat surface while glue dries to ensure that the pieces remain flat Front Frame Pieces Rear Frame Pieces ...

Page 13: ...rame pieces interior face up as shown below apply a small amount of glue around the rim of each of the 3 8 holes in the frames and insert a nylon shoulder washer It might be necessary to firmly press into place or to tap in with a hammer Be sure the washers gets seated completely into the holes Flip the front frame over and likewise insert one shoulder washer into the endmost hole indicated in the...

Page 14: ...13 Crutch Arm Assembly Parts 1 Crutch arm 24 1 3 4 dowel Assembly Procedure Glue the 3 4 dowel into the crutch arm 24 Be sure the crutch arm is oriented as shown below ...

Page 15: ...cess glue from the slotted portion Set the tee nut in the slot in the pendulum back with the barrel in the slot and the flat part facing up Orient the nut so that it falls past the interior piece and drops all the way down in the slot Glue the pendulum bob front piece 43 onto the interior piece keeping glue away from the slotted portion Verify that the T nut slides freely along the length of the s...

Page 16: ...mbled previously Assembly Procedure 1 Sand edges of the two shaft pieces Glue together the upper and lower pendulum shafts with the dowels glued into the holes pinning the pieces together Make sure the upper shaft piece 37 is on top of the lower shaft piece 14 2 Touch up sand the pendulum edges where they overlap 3 Drive the two 4 x screws into the predrilled holes in the pendulum bracket 32 37 14...

Page 17: ...ach the crutch arm to the pendulum shaft with a 4 x screw The screw should be tight enough to hold the crutch arm in place the exact position will be adjusted later 5 Flip the pendulum shaft over and rest it on the back side of the pendulum bob assembled previously Attach the shaft with the thumbscrew engaged with the t nut in the bob Tighten snugly enough to keep the bob in place the exact positi...

Page 18: ...ont to back and oriented as shown below 40 38 39 39 39 41 20 with the two dowels inserted in the holes on either end of the shell Note that the cutouts of the interior pieces have a curved end and a straight end make sure the ends are oriented as shown below 2 After the glue is dry sand and finish the weight shell and cover 21 3 Carefully fill the shell with metal shot As the shot nears the rim jo...

Page 19: ...r the glue has dried sand these three subassemblies Next sand smooth the center portion of the 1 dowel Insert the dowel into the pulley wheel sand more as needed to ensure that the wheel spins freely Coat the middle portion of the dowel with graphite pencil lead Finally glue together the three subassemblies with the pulley dowel engaged into the two holes on the inside faces of the hook unit sides...

Page 20: ...and winding hub 51 together in the order shown Be careful to orient the rachet teeth as shown Use a piece of 1 4 dowel or a drill bit to help align the pieces and to clear the center hole of excess glue remove dowel before glue sets It is critical that the glue bond between all of the spool pieces are solid ensure adequate glue coverage and clamp time 3 Pull the cord through the spool divider 49 u...

Page 21: ...hub in a counter clockwise direction Continue winding until about 16 of cord remains 6 With the rachet in the same position wind the other length of cord 3 times around the smaller hub in a clockwise direction nearly 7 feet of cord will remain 7 Secure the two strings with a piece of tape so they do not come unwound during the upcoming assembly sequence ...

Page 22: ...gaged in the gear place the gear on two boards or blocks with a gap slightly wider than the dowel Continue to drive the arbor through the gear until it arrives at the marked location on the arbor Do not glue the gears in place yet their positions may need to be adjusted after the clock is assembled Important After gears have been properly positioned on arbors use fine sandpaper 220 grit or higher ...

Page 23: ...owel to clear any excess glue from the inside of the minute pipe 2 After minute pipe glue is completely cured use a hammer to gently tap the minute pipe into the 32 tooth gear 3 Press the hour hand 17 onto the minute pipe Do not glue in place The friction fit should be tight enough to keep the hand in place yet still allow the hand to be rotated on the minute pipe ...

Page 24: ...heel Pawls Part 2 Rachet pawls 48 1 64 tooth great wheel 1 Assembly Procedure Glue the rachet pawls into the slots in the great wheel gear spoke Make sure the pawls are oriented in the great wheel as shown below ...

Page 25: ...hers 42 1 2 3 4 dowel Assembly Procedure Mount the 60 tooth gear and 8 tooth gear on the arbor in the positions indicated in the Gear Location Diagram Place a spacer washer on both ends of the arbor Gear Locations 8 tooth gear 60 tooth gear spacer washer spacer washer 2 3 4in ...

Page 26: ...be installed on this arbor after clock is assembled Assembly Procedure Mount the 8 tooth gear and the escape wheel on the arbor in the positions indicated in the Gear Locations Diagram below Be sure the teeth of the escape wheel are oriented as shown below Place a spacer washer on both ends of the arbor Gear Locations ...

Page 27: ...andpaper on a smooth hard surface and lightly sand these two contact faces making sure not to alter the angle or flatness of the faces Repeat with 400 grit sandpaper Then apply pencil lead to the contact faces Mount escape lever and the crutch on the arbor in positions indicated in the Gear Locations diagram The escape lever must be oriented as shown below Mount the set washer and place a spacer w...

Page 28: ...rachet pawl must be toward the long end of the arbor Slide weight spool rachet side first onto the arbor Twist the spool so the rachet teeth mesh with the pawl Slide a spacer washer onto the arbor tight to the spool Mount the 10 tooth gear on the arbor bringing it nearly in contact with the spacer washer leave about 1 16 gap so that the spool is free to rotate on the shaft without binding Mount th...

Page 29: ...28 Gear Locations ...

Page 30: ... 2 spacer washers will be installed on the arbor after it is inserted in the frame Assembly Procedure Mount the set washer and 30 tooth gear on the arbor in locations indicated in Gear Locations diagram 8 tooth gear and spacer washers will be mounted after arbor is mounted in frame Gear Locations ...

Page 31: ...asher 13 1 2 15 16 dowel Pulley Wheel assembled previously Assembly Mount the set washers and pulley wheel on the arbor in the locations shown in the Gear Locations diagram Leave enough clearance between the washers and pulley wheel so the wheel can spin freely Gear Locations ...

Page 32: ...arbor Mid wheel arbor Great wheel arbor Minute wheel arbor Weight pulley Winding guide arbor 32 tooth gear with minute pipe and hour hand Assembly Procedure 1 Set the rear frame unit on a flat surface with the interior face the side containing the shoulder washers up Insert the escape lever into the topmost bushing with the escape lever down and the crutch up Be sure that a spacer washer is locate...

Page 33: ... there is a spacer washer at both ends of the arbor The 60 tooth gear should mate with the 8 tooth gear on the escape wheel arbor 4 Insert the great wheel arbor into the next available bushing with the 64 tooth gear down Be sure there is a spacer washer adjacent to the 64 tooth gear The 64 tooth gear should mate with the 8 tooth gear on the mid arbor Note the 10 tooth gear on the great wheel arbor...

Page 34: ...wo spacer washers onto the arbor protruding through the front of the frame and complete by installing the remaining 8 tooth gear on the arbor Adjust the position of the spacer washer and or 8 tooth gear so the arbor can spin freely in the bushings 7 This might take a little patience Carefully attach the front frame unit Note that the escape wheel arbor and great wheel arbors extend through the fro...

Page 35: ...lower pillar Then route this cord through the weight pulley and back up to the pillar tying off the cord in the hole in the bottom of the lower pillar Make sure the weight pulley hook is oriented as shown below Be sure the knot is secure since it will be supporting the weight shell 10 Place a set washer on the great wheel arbor that extends through the front frame Locate the set washer so that the...

Page 36: ...tated to a new position the hands cannot be glued to the arbor If either of the hands is too loose causing the hands to slip apply a small amount of glue to the shaft to build it up slightly Allow to dry completely before attaching hand If the hands are too tight sand the shaft or interior hole of the hand 12 Attach the second hand to the escape wheel arbor protruding through top of front frame It...

Page 37: ...ou predrill a 1 8 pilot hole in the wall Sink the hanger bolt until there is a gap of approximately 3 8 between the acorn nut and the wall 3 Remove the acorn nut from the hanger bolt leaving the hanger bolt in the wall 4 Hang the clock on the hanger bolt through the hole in the rear frame Place a washer on the hanger bolt followed by the acorn nut Orient the clock frame approximately as shown belo...

Page 38: ...This adjustment is made by rotating the pendulum support plate in the top pillar Once the proper position of the pendulum is established the screw holding the support plate into the pillar can be fully tightened Also check that both of the screws are resting on the support plate If necessary raise or lower one of the screws so that they both bear on the support plate and allow the pendulum to be i...

Page 39: ...lows over the pulley wheel in the lower pillar then down and back up around the pulley wheel in the weight hook Make sure the rewind cord which comes off the smaller hub of the weight spool follows over the pulley wheel on the winding guide 14 Adjust the pendulum bob s orientation until its midline is in a vertical position The thumbscrew on the back of the bob can be loosened or tightened to aid ...

Page 40: ...he hook onto the dowel in the top of the weight shell 14 At this point some adjustments will likely be needed to get the clock running For now give the pendulum a slight push to the side and release to see if the clock will start running Then continue on to the next section of the instructions ...

Page 41: ... left tip of the lever Adjust until the pendulum will make several oscillations before stopping Small adjustments of the clock s vertical position should bring the clock into beat The vertical orientation of any pendulum clock is critical Once the clock s correct position is established tighten the acorn nut to firmly secure the clock to the wall If needed an additional anchor can be added Mark on...

Page 42: ...will in the future 6 Winding the clock Wind the clock by pulling downward on the rewind pull or rewind cord with your left hand while simultaneously lifting the weight with your right hand It will take some practice to get the feel for this Verify that neither cord has jumped off of its pulley If necessary restart the pendulum after winding The clock should run for over 30 hours on one winding 7 F...

Page 43: ...en the spacers and the nylon bearings Gear alignment Check to see that each gear is aligned with its mating gear Reposition gears on the shaft as necessary so that mating gears fall in line with each other Gear positions Each gear should mesh smoothly and easily with its mate with a small amount of play between the mating teeth Double check the assembly instructions to be sure the correct gear is ...

Page 44: ...ver and crutch are not loose enough to slip Glue any components as necessary Crutch slot clearance It is important to have the proper fit between the pendulum shaft and the crutch slot Friction between the crutch forks and the pendulum shaft can rob energy from the clock and return the pendulum to a stop The space between the crutch forks should be equal to the width of the pendulum shaft plus the...

Page 45: ... find it more difficult to keep the clock running on time Technical Support We are available by telephone or email to assist you with any problems or to answer any questions you have while you are building your clock Do not hesitate to contact us for assistance E mail jeff wooden gear clocks com Telephone 715 955 4104 Comments We d love to hear from you about your experience with the Crescent cloc...

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