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docp - 2012-02-21 05:22

I'll post a picture shortly...

There are two different designs of the main hybrid magnetic clutch gear Sony used.

a) One with the central metal and peripheral plastic...which has caused so much agony, misery,curiosity & creativity to keep it going &

b) The more obscure variation...a complete plastic gear wheel with the metallic portion stuck on...zero failure. I first came across this type courtesy member Autoreverser.

I'll post a picture in a few hours ( nothing like a bit of suspense and mystery)

brutus442 - 2012-02-21 07:49

You just did this for dramatic effect didn't you DocP??

Keep the audience in suspense...you are cruel..

docp - 2012-02-22 05:14

Now that I have milked the moment for maximum effect

Kindly correct me if I am wrong....I think this wheel featured in the later DD walkmans like DD30 and doesn't have the suicide prone kamikaze design of the normal outer plastic rim gear wheel we see failing....

docp - 2012-02-22 05:20

The gear wheel is ridiculously simple to replicate and it is possible to add a simple steel washer into the replica by placing a washer into the mold before filling the plastic in...the plastic 'sticks' to the under surface. Or a washer could just be stuck on with super glue 'mimicking' the original design. My duplicating skills failed me when it came to the central /axle gear teeth. This wheel has a removable central component with tiny gear teeth. I almost thought of getting that portion made in brass but gave up as mine was solely for 'academic' curiosity as I only have one DD walkman that too a kind gift from Autoreverser to try the replicas on

I am hoping someone can take off from where I left off

brutus442 - 2012-02-22 05:33

Interesting idea Docp!

Question from the non owners club...would the metal washer be too heavy for the motor to play for any lengthy duration and what effect would it have on battery life?

docp - 2012-02-22 05:57

The original metal 'washer' stuck onto the gearwheel appears to be 6mm thick. I tried two variations ...sticking similarly thin washers of equal diameters and slightly smaller (not much difference in the magnetic clutching). If a washer is thicker I'd just go with the packing of plastic over it in the split mold allowing it to slightly ember itself into the plastic...

EDIT : silly me...the washer is 0.6mm thick

brutus442 - 2012-02-22 06:00

With a 6mm gearwheel that motor could certainly handle a thin washer. Wow I didn't realize it was that thick!

docp - 2012-02-22 07:58

Oooooops I missed out a '.'

0.6mm /half a mm ...quite a thin washer actually

brutus442 - 2012-02-22 08:04

Aha! I hope this makes up for the "T" I owe you!

docp - 2012-02-22 08:11

Ha ha

....I knew you'd catch me on that one

....so I decided to leave the error in place to entertain

Yikes ! Imagine a well wisher making a DD gear with a bulky 6mm washer added on....like those "concrete boots" to sink folks in old gangster movies

brutus442 - 2012-02-22 08:17

Just don't slip those gears around my neck, next time I swim DocP!