Hi All, wanted to share my latest project with you. I have a very nice Philips D8614 boombox which, as usually, also suffers from the weak gear syndrome. This one didn't rewind or forward anymore because gear part no. 482240340117 was completely disintegrated. So I decided to make a repro.....

Above the original gear as I found it inside the box. Luckily there is just enough left to determine the original diameter...

The machine I'm going to use is a Lasercutter (see below). It's some kind of plotter, but it uses a laser instead of pens and ink. It can cut various materials like wood and plastics. In this case I'm going to use PMMA as base material. Mainly because I already know the various machine settings for this material. Next gears are going to be of POM. This is THE material for this kind of gears and the laser can handle it easily. I just have to do a lot of experimenting to find the proper machine settings....

On the next photo is the drawing of the gear, ready to be shot into the laser. Note the small bush right to the gear. This will be the hub of the gear. It will be cut out of a baseplate with bigger thickness, as the machine is only capable of 2D operations. The hole in the gear will be 0.1 mm smaller than the outer diameter of the bush. This way it has a nice tight fit and no glue is needed.

Next photo is the base material for the gear ready to be cut....

A short clip of the actual cutting can be found here on YT. Its a little difficult to film, but it will give an impression of the speed of the process....

http://youtu.be/8cZ0ElkCd1A

After pushing the hub into the gear the part looks like this....

The part assembled onto its supporting lever....

And into the tape drive...

Rewinding and forwarding works great now! Smooth and stable. Like new actually.... I like my D8614 again!

What a terrific job Michiel! I think this experiment of yours may be extremely useful to Walkman fans too! If you are willing to help members, consider me n.1 in your list: my 8614 suffers from exactly the same problem you so brilliantly solved

top draw mate a handy option  .

Good job!

Now you just need to make us all some DD centre gears.

naughty plop  

Yeah, I know... A DD centre gear would be cool.. I've got two of these with cracked gears. But it's rather difficult to make cause its really a 3D gear. Have to find a way to combine 2D objects into a complete centre gear. But I just started lol...

First priority are my two Philips D8444 boxes, both with cracked gears. My goal is to get them fit enough for the next 30 years haha...

This is fantastic. Well done.

I wonder if the 3D plastic printers that are available now could handle the DD type gears that seem to be a problem? I can't imagine any other process would be viable for low volume production.

If it's possible it would still be pricey; maybe £30 per gear. Would folks pay that much?

I was thinking the same...here at S2G you've a ready market! Oh, and great job Michiel, very clever

WOW

What a machine dude

I know the problem with the philips, I had 8444 with same issue and another one I forget the number, lucky I had scrap 8444 to rob for parts

That is amazing work though

great stuff, always love to hear of 8614's being saved, lovely job

Hi I could do with some gears fella,i need two for my D8644,gear on the play to centre capstan gear and small gear for fast forward sections.One is completely toothless and the other has a few left and both wheels are a horrible yellow color,i found bits of these inside boombox I just bought 2 days ago on fleebay.. gutted!Can you do me some spares and how much? Great idea you got there fella you could reserect a lot of ghettoblasters back from the dead dude!!

LOVE IT! Great Job Michiel!

Let us hope that 3D printers and laserprinters become our NextGen saviours for weak parts

Hi Boombastic, is it a spur gear? Can you post a pic of the gear?

Hi Michiel, i will open the D8644 and take some pictures for you,iam not sure what the gear is called,it sits in between the centre capstan and another gear,looks like the one you have pictured at top of page only this one as no teeth,its approximately 2cm and 2 mm wide  thats what i measured it to be but that may not be accurate,i will measure them properly tommorrow and post for you,i need the other for the fast forward aswell.Thank you for your quick reply,i will get photos asap.Well done to you for your abilites.

I buying that laser cutter. Unfortunately my 3d printers can't do precision work due to stepper motors. But now I see the price came down on theses I want one. But then next generation machines are going on the market soon?

@Boombastic; the left gaer on the pic looks very similair to the helical gear VintageVolts made. I gues this box is also produced by Philips Singapore? You could ask him for the diameter etc to be sure... I think I have the right gear in my possession en wil try to make a replication of it..... 

LINK ERROR.5#317390672478461565

@retrodus; I've got acces to a first or second generation Makerbot, but I'm pretty sure the resolution isn't enough for this kind of jobs.. Laserprinters are certainly progressing. There are even types that can cut traces on electronic boards. This one can't unfortunataly.... Take note that the these gears have a module of 0,5... Rather big.. Compared to the the dd gear, which has a much smaller module... 1/3 of the Philips gears above I gues... 

@Boombastic, Yep, I got the rewind gear on the right side of the pic. Shouldn't be to difficult to replicate it. Will try to do it next week.... Let u know...

Today I made the drawing. I'll do the gear next to it as well... In some boxes the gear next to yours is from the same weak material. Like the D8169 I use to get the measurements from...... Hope to push it into the printer begin of next week. If I got the material.

Here a small report about reproducing the rewind and forward gears for the Philips D8444 (and other) boombox on the laser cutter. This gear was different from the earlier gear, because it has a ridge in the inner hole for fixing the gear to the shaft. So I had to design some extra parts for fixing. A shim and a fixation clip. These parts are also laser cut....

I have made three sets. Two for my D8444 boomboxes and a set for Boombastic. He is gonna be the guinea pig... I haven't tested the gears yet, but I think they will work.... Boombastic, can you pm your address?

The drawing of both gears, the gear hub, the shims and the fixation clips.



Small YT movie of the cutting process....

http://youtu.be/WLHME5fmNkk


All the parts together....


The completed gears next to the originals....

Hi,brilliant work,i will need these as I bought another D8644 off fleebay and will need them as it suffers the same symtoms of play problems as my first D8644,i should receive the 2nd D8644 tomorrow. I will send you my address when I figure-out how to PM you.

Check at Dialogs, above on your screen... I send u a pm, try if u can reply it...

New Philips rew/fwd mounted on their supports in the deck.... Works!..

genius at work!

Me no genius.. it's this amazing machine! I administer it for two years now, but I never bothered to do something with it.. till now...

Today I got the control gears out of my spare Philips D8614 to make new ones. The big gear is a helical gear. So I also have to replace the motor gear. Think this is gonna work.. Just have to order the materials so I can start the project....

good work michiel !  

  now we know who to go to for boombox gears,  thanks for sharing Michiel

One could always contact. But I've got many projects going. Didn't even finish the Philips deck control gear yet 

Hello Michiel,

I also desperately need the well-known gear (helical plus straight) for my D8444. It just cracked into 4 pieces!

I cannot add a picture so easily here. I'm quite sure you know what gear I mean. The one that's driven from the flywheel, and has a small pinion also. It is, in other words, a reduction gear. The others are - for the time being - still OK, but would it make sense to replace them also? I'm quite new to this problem!

Thank you in advance,

Timmo.

Hey Timmo, unfortunately I'm not able to make the helical gear for the D8444. There was a member making them with an 3D printer, but haven't seen him for a while....

The good news is... You will find the same deck and gears in many newer (90's) Moving Sound Philips boomboxes. Most of the time the gears are still in great shape, because the boxes are less old. You will recognize them by the tapedeck keys layout. I will have a look tonight if I can find you a model number....

Where can I buy such a gear 482240340117? What is the price?

Who can help me?I repaired a tape deck but now the winding and rewinding was

 not good.I found the gear with missing teeths!

Moving Sound Philips boomboxes
ok Which model is the: 
Moving Sound Philips boombox?
is it perhaps this model:
Philips moving sound D8088?
or a Philips Moving Sound D8304
and the aka of that is a Magnavox D8300
which Model of the (Moving Sound Philips boombox) can this gear
be found in to the best of your Knowledge?

A seller on eBay was selling them, but it looks like he doesnt have them anymore.

http://www.ebay.ca/itm/Philips...340117-/260754818513

Hi everyone, found out this topic only days ago after years of looking for an answer.

I need help with this gear. It comes from a Philips AZ 8300/04.

It's the gear responsible for moving the cd lens forward and backward (or left and right)

I've search everywhere and even on the service manual I couldn't get a serial number or something.

As you can see from the photos the bigger part is intact, the problem is on the small longer part that is ruined. Is there a way to buy this particular gear?

Thanks for any kind reply.

Hi Michael. I have a Philips D8614 and I have the same problem as you with the gear. Please Do you have a drawing of the sprocket? If so, could you send it to me please? Thank you for your response. Have a nice day. Mirek

Hi Mirek,

I have the same problem withe a "Radiola" D8614. I think the only solution is to make a 3d model of the "orange" gear and 3D print it. I have started a modelization of this gear, so stay tuned.

Great development Wiizzz!, keep us informed please! 

Tadaaa! :

I will post the 3d file as soon as I have printed and tested the gear in my D8614

Great job wiizzz, looking forward to seeing the results.

Thanks Retro

Hi guys,

I have reached my goals, All as I have wanted Is to play this kind of thing in my boombox :

I can do Play, pause, stop, eject and its all whats I wants. fast forward, rewind and record still doesn't works. I do have other gear problems I think. But who cares with this type of cassette...

Here is the photo of my spare printed gear, It was printed in PLA in an Ultimaker printer, as you can see the quality is not perfect :

I have also included my *.stl 3d, with the correct 20° angle (thanks Virgil) model in attachment for those who need it.

Hi Wiizzz.Excellent work,congratulations.You please drawing ?I have bad two wheels,it made me troubled and I would like to solve this problem.I'll be glad for any help from all the people what are here in the forum.Thank you so much

Hello everybody,
I heard about the possibility that old Philips-gears can be remade here.
As previous speakers, I have the same problem with defective gears.
In my Philips Boombox D8088 both tape decks work no longer, since both drive gears are worn (orange gears on the back of the drive unit).
Can the orange gears from the Boombox D8088 also be remade?
What are the costs for spare parts?

Thank you for a short info on this!

Best regards!
Lutz

Hey Michiel, could you post/share the files for the laser cut gears? I have a d8614 and the gear broke yesterday. I'd like to try to reproduce the gear as well.

traxxasislife posted:

Hey Michiel, could you post/share the files for the laser cut gears? I have a d8614 and the gear broke yesterday. I'd like to try to reproduce the gear as well.

and when EVER !! ANYBODY make these &*()&*(*(& Gears I need Three of them and thank you

JamesRC550 posted:

traxxasislife posted:

Hey Michiel, could you post/share the files for the laser cut gears? I have a d8614 and the gear broke yesterday. I'd like to try to reproduce the gear as well.

and when EVER !! ANYBODY make these &*()&*(*(& Gears I need Three of them and thank you

I have access to a laser cutter. If I can get the files from MICHIEL I can see about having a couple made.