I thought I would post a few pictures of a repair I made to the crank handle on my saw.
A little history: I recieved the saw from a freind because he was getting a new saw and didn't need this one any more. This saw had a few problems, one being the height adjustment. (See my post on this forum: "BT3K height adj. repair".) As well as the crank being broken.
This first picture is a before shot. Take notice of the small star shaped bushing in the center of the handle. There are 2 of them and they will be re-used, so don't discard them.
I took the broken piece with me to my local hardware store, and went on my quest for some PVC replacement parts. I have a set of dial calipers that really helps in getting a tight fit for the part.
Here is the result of my searches. I found that a 1" pvc threaded nipple (Lowes SKU # 23858 $0.40)had the closest ID to the original handle. After a lot searching for something smaller, I could not find anything else that would fit as closely.
Next what I did was take the original star washers from the broken handle and flattened them out a little on the bench so they would fit more snug inside the PVC nipple.
With the nipple facing threaded side up on the bench, I used a deep socket that fit just inside the nipple and tapped in the first star washer down into the nipple approximately 3/4"-1" with a hammer.
Next I tapped the other star washer into the nipple (again threaded side up on the bench) into the nipple approximately 1/4" inches into the nipple.
Once the washers were in and secure, I cut a piece of 1" PVC pipe (Lowes SKU # 23977 $2.17) and used some PVC glue (Lowes SKU # 23540 $$2.94) to assemble the pipe to the nipple. I dropped the original pin from the original handle into the nipple through the star washers. I used a small 3/8" nut as a spacer between the pin and the star washers so it wouldn't protrude too far into the crank wheel after completed.
(Note: Make sure that when you tighten the handle to the crank wheel, you mount it as close to the crank as possible still retaining a smooth operation. It is my feeling that if you have the handle too far away from the crank wheel it will eventually work the star washers loose.)
Finally, I took a rounded Cap (Lowes SKU # 23897 $0.41) and drilled a 1/2" hole in the end in case I ever needed to get the pin out of the assy, and glued it flush to the protruding 1" PVC pipe.
Here is the result on the Saw. It works very well and has a good feel. It is a little larger that the original handle, but I think it aids in cranking up the saw.
Total cost of the repair: $6.40
Enjoy!
A little history: I recieved the saw from a freind because he was getting a new saw and didn't need this one any more. This saw had a few problems, one being the height adjustment. (See my post on this forum: "BT3K height adj. repair".) As well as the crank being broken.
This first picture is a before shot. Take notice of the small star shaped bushing in the center of the handle. There are 2 of them and they will be re-used, so don't discard them.
I took the broken piece with me to my local hardware store, and went on my quest for some PVC replacement parts. I have a set of dial calipers that really helps in getting a tight fit for the part.
Here is the result of my searches. I found that a 1" pvc threaded nipple (Lowes SKU # 23858 $0.40)had the closest ID to the original handle. After a lot searching for something smaller, I could not find anything else that would fit as closely.
Next what I did was take the original star washers from the broken handle and flattened them out a little on the bench so they would fit more snug inside the PVC nipple.
With the nipple facing threaded side up on the bench, I used a deep socket that fit just inside the nipple and tapped in the first star washer down into the nipple approximately 3/4"-1" with a hammer.
Next I tapped the other star washer into the nipple (again threaded side up on the bench) into the nipple approximately 1/4" inches into the nipple.
Once the washers were in and secure, I cut a piece of 1" PVC pipe (Lowes SKU # 23977 $2.17) and used some PVC glue (Lowes SKU # 23540 $$2.94) to assemble the pipe to the nipple. I dropped the original pin from the original handle into the nipple through the star washers. I used a small 3/8" nut as a spacer between the pin and the star washers so it wouldn't protrude too far into the crank wheel after completed.
(Note: Make sure that when you tighten the handle to the crank wheel, you mount it as close to the crank as possible still retaining a smooth operation. It is my feeling that if you have the handle too far away from the crank wheel it will eventually work the star washers loose.)
Finally, I took a rounded Cap (Lowes SKU # 23897 $0.41) and drilled a 1/2" hole in the end in case I ever needed to get the pin out of the assy, and glued it flush to the protruding 1" PVC pipe.
Here is the result on the Saw. It works very well and has a good feel. It is a little larger that the original handle, but I think it aids in cranking up the saw.
Total cost of the repair: $6.40
Enjoy!
LCHIEN
Loring in Katy, TX USA
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