Took some time out this afternoon for TEA...
and a little "MacGyver-fyin'... "
I've had this beat up old Hitachi V-212 for decades; kept it in a corner hooked up to a super simple curve tracer for quick Go/No-Go testing of various components. It's had the Voltage VAR/5X Gain knob busted off the CH2 timebase since I got it; on the very rare occasion I actually needed that function on the 'scope, I just used a pliers as most of the time it was on X-Y mode anyways.
Well... As y'all know I'm hoeing out my office... and the time came this afternoon to pass final judgement on the old beast as far as "Keep or Get Rid Of". The only thing I could think of where it really shines was as a "First 'scope"; so I decided that if I could get it operating passably on all functions in an afternoon, I'd keep it for my son.
After investigating fleaBay in search of usable parts units, I found nothing I considered reasonable price for a 30-year-old 20MHz School Lab 'scope; so decided to get medieval on it's ass.
First, I put a plastic prophylactic all over the outside of the unit, since I knew I was going to be grinding and brass powder was going to go everywhere. Then I pulled out the shaft, and ground a bevel across all that was accessible using a cordless Dremel and 1/2" sanding drum.
Next, I cut apart a 4mm gold-plated banana plug to get something I could whittle down to a matching shaft diameter with a similar bevel. Resizing the shaft was done by chucking up the banana plug in a drill press then cutting it down with a cordless Dremel, then finishing with a file. Bevel was cut using cordless Dremel and same sanding drum.
[EDITED TO INTRODUCE DETAILED TECHNIQUE AND SOME COMMON SENSE]
Next, I tinned the bevel portion of original shaft and new knob; careful application of flux and working quick & hot kept solder only where I wanted it.
I'm using
lead-free solder for this work; while it is harder to work with, it makes a
much stronger joint in applications like this where the solder has to fill gaps. Just
remember to desolder the mating surfaces clean and apply fresh flux (regular rosin flux works great) every time you make an attempt at joining the two pieces.
Solder-wick clean is about right; whether you get there using solder-wick or wiping with soldering iron tip if your soldering technique is that advanced.
Then came the fun (read frustrating & repetitive) part; soldering the two together. I puttered around far too long with trying to make one of my helping hands or many vises hold the new knob just right to solder it up square & concentric and had abysmal luck.
I know, you'll probably say I'm crazy for saying this; but I've found long ago that you can get pretty damn close by feel & eyeball, as long as you can actually put fingers on the work. After dozens of attempts with vises and helping hands and holding it with hemostats, I finally gave up and did it the hard way, just like I knew I'd have to from the outset: Hold it by hand and solder it hot & quick so I could let go of it before the heat got to the part I was holding.
This method took me 3 tries before I had it nearly PERFECT.
If you don't have the correct tools (150-ish watt iron at 700 degrees F and advanced soldering skills) I recommend you do it the long hard way: Jig up the part to be repaired or use hemostats to hold the part and just be patient and willing to try dozens of times before you get it right. Your fingums will thank you for your patience.[EDIT]
A little filing and sanding, and the shaft was repaired; then a little hot-glue inside the knob cap and pop it on while the glue's still hot...
...and it was ready for testing. I did the usual clean switches with a squirt of alcohol then dust out with compressed air; wiped down the front a little too. The bezel's been missing since I got it (well, there was a little broken piece under the CRT I took off and threw away); but for this purpose, pretty is as pretty does. If it's still humming away like this when I wake up in the morning, it'll go in the closet for future lesson time with my son.
Cheers,
mnem
*Goes to lie down before he falls down*