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    Repair Vintage Temperature Gauge

    Uploaded by

    Yves de Ryckel
    This document provides instructions for easily repairing a broken temperature gauge using common household items. The key steps are: 1. Dismantle the gauge and sensor to access the capillary tube. Replace any damaged parts with new tubes. 2. Refill the sensor bulb with ether using an innovative method that takes advantage of temperature differences to pump the ether in. 3. Reassemble the gauge, soldering all connections to be airtight. Test the repaired gauge to ensure it provides accurate temperature readings again.

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    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd

    Repair Vintage Temperature Gauge

    Uploaded by

    Yves de Ryckel
    735 views7 pages
    This document provides instructions for easily repairing a broken temperature gauge using common household items. The key steps are: 1. Dismantle the gauge and sensor to access the capillary tube. Replace any damaged parts with new tubes. 2. Refill the sensor bulb with ether using an innovative method that takes advantage of temperature differences to pump the ether in. 3. Reassemble the gauge, soldering all connections to be airtight. Test the repaired gauge to ensure it provides accurate temperature readings again.

    Original Description:

    How to repair classic car temperature gauge with a bourdon tube. Refill technique.

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    © © All Rights Reserved

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    This document provides instructions for easily repairing a broken temperature gauge using common household items. The key steps are: 1. Dismantle the gauge and sensor to access the capillary tube. Replace any damaged parts with new tubes. 2. Refill the sensor bulb with ether using an innovative method that takes advantage of temperature differences to pump the ether in. 3. Reassemble the gauge, soldering all connections to be airtight. Test the repaired gauge to ensure it provides accurate temperature readings again.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    735 views7 pages

    Repair Vintage Temperature Gauge

    Uploaded by

    Yves de Ryckel
    This document provides instructions for easily repairing a broken temperature gauge using common household items. The key steps are: 1. Dismantle the gauge and sensor to access the capillary tube. Replace any damaged parts with new tubes. 2. Refill the sensor bulb with ether using an innovative method that takes advantage of temperature differences to pump the ether in. 3. Reassemble the gauge, soldering all connections to be airtight. Test the repaired gauge to ensure it provides accurate temperature readings again.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 7

    AneasymethodtorepairaTemperatureGauge.

    Afterafewunsuccessfultrials,hereisthedescriptionofaneasymethodtorepairandrefillabroken
    temperaturegauge.
    ThepartsyouneedtorestoreyouroriginalTemperaturegaugeareshownonthefollowingpicture:

    Oldsensor
    Thegaugewithapieceofcapillarytubeandtheconnectingsleeveortermination
    Acapillarytubeifyoucannotaffordtousetheremaininglengthonyourbrokengauge.
    EtheroraStartPilotspray
    52Csprayusedtodebugelectroniccircuits.(seeetherrefillparagraph)
    apieceofheatshrinkablesleve(about45mmdia.)

    Youwillneedtobuyanewcapillarytube(lengthofabout22andexternaldiameterofa.078to.08)(ebay)
    andanewbindingwrap.(Ivefoundalongcapillarytubefromanoldgas/butanerefrigatorsafetyswitch)

    YvesYLG80Belgiumwww.aviplus.com

    Dismantling
    Openthegaugecase(seealsoFuelGaugerepaironG503
    http://www.g503.com/forums/viewtopic.php?t=118652)
    Ifyouhavetoreplacethecompletecapillaryline,heatupthegaugeterminationinordertoremovethepieceof
    capillarytubeandthesleeve.

    Heatupthesensorinordertoremovebothpiecesofthecapillarytube
    (Theveryendbendedpieceofcapillarytubeistobeusedtorefillthesensorwithetherbymeansofaused
    medicalsyringe.)

    Theshortlengthofcapillarytubeisusedtorefillthesensor.Whenthebulbisfullofether,youjustneedto
    crimpthecapillarytubeat2or3locationsandthenapplytinsoldertopermantlyclosethetube.
    Careshouldbetakentotoroughlycleanuptheclosingsleeveandtinthejointsurfacepriortoresolderit.

    YvesYLG80Belgiumwww.aviplus.com

    Theonlycriticalthingsare:

    aperfectcutofthecapillarytube.IveusedmyProxxondrill(orthewellknownDremelifyouwant)
    withacuttingdisc.(donotusecuttingpliers!)Thisisacoppertube,soitsnotdifficulttocut.
    Avoidpluggingthecapillarytubewithtin.Dothis:

    Perfectlysolderthesensorinordertoavoidanyetherleaks.
    DontsufferfromtheMurphylaw:
    Donotforgettoinsertthecapillarytubeintothewire/flatwrap
    ANDthethreadedbrassplugANDthegaugecanBEFOREsolderingtheelements!

    Hereisapictureofhowitlookslikebeforerefillingthegauge(pic.2)

    YvesYLG80Belgiumwww.aviplus.com


    Usetinsolderwithflux(liketheelectronicsolder)removethefluxexcessoncethesolderingiscomplete.

    Useablowtorchwithfinetiplikethisorapowerfullsolderingiron(100150W).
    ThiscouldalsobedonewithahotgunintheHighPowerposition.
    Onceyouareplayingwithether,donolongeruseanyequipmentwithanopenflame.
    Ifyouhavemissedtherefillanddecidetotoremovethecapillaryterminationandrestarttherefillproces,
    dontforgetnottouseopenflamebecausethereislikelystillasmallquantityofetherinthegauge.
    ContrarytowhatIveread,youcanrepeattheprocessseveraltimesaslongasyoudontmodifythebourdon
    springmechanism.
    Precautions:
    ALWAYSHEATUPTHEMETALPARTSANDNOTTHESOLDER!
    Applytinfirstonyoursolderingiron(wettip)
    Heatupthesleevesorbulbratherthanthecapillarytubeitself.
    Thecapillarytubewillheatupaswellandwhenyouapplythesolderagainstthecapillarytubeand/orthe
    sleeve,itwillmeltandenterinthesleevehole.
    Whenyousolderthecapillarytubetotheclosingsleeve,youshouldseethesoldersuddentlyenteringinthe
    sleeve.Thisinsurethatthetubeissolderedinsidethesleeve.
    Neverblowupthesolderjointtoacceleratethecooling.Letitcooldownnaturally.
    Wheneverythinghasbeensoldered,verifythatyouhavenotpluggedthecapillarytube.Blowairfromthegauge
    sideandseebubblesinwaterfromthefillingend.
    Plugthefillingendwithyoufinger,blowagainthroughthecapillarytubeandverifyiftherearenoleaksfrom
    thebulb.
    Yoursensorshouldsomewhatlooklikethis:(seenextpage)

    YvesYLG80Belgiumwww.aviplus.com


    Note: Ivetestedthequantitytofillinthebulb(withmethanol)beforesolderingeverything.
    Youwillneedapprox2.53mlofether.

    Torefillthegaugewewillneedether.
    EtherislikelydifficulttobuynowadaysandyoucoulduseaStartPilotspray.
    Theyareusingethertohelpstartingengines.
    Etherisreallyverydifficulttohandleasitevaporatesatmoreorlessthan35C.(boilingpoint).
    Itsalsoaverygoodorganicsolvantwhichdoesnotreallyhelpinourmatter.

    Soyouwouldbetterworkinacoldroom.(IvecompletedtheoperationinmygaragewhiletheTwasabout
    6C.)
    (Iveevenworkedjustaboveanhorizontaldeepfreezer(18C)duringmyothertests.Itjusttake2or3minutes
    todotheoperation.)
    YvesYLG80Belgiumwww.aviplus.com

    Theeasytrick!
    Forgettotrytouseasyringewithaneedleandinjecttheetherinthebulb.
    Theetherwillfloweverywhereexceptinthebulbanditwillsmeltlikeinanhospital.
    (Imafraiditwasevendissolvingplasticaroundthemetalneedle.)
    Perhapsyouwillevenfallasleep!

    After2unsuccessfultrials,Ifinallydecidedtotestaveryoldrule,theBoyle&Mariotterule:
    Theabsolutepressureexertedbyagivenmassofanidealgasisinverselyproportionaltothevolumeitoccupies
    ifthetemperatureandamountofgasremainunchangedwithinaclosedsystem
    AsIwasunabletoinjectenoughetherinthegauge,ItoughtusingtheB&Mruletopumptheether.
    Ifitsnotpossibletoinjectether,letthegaugepumptheetherbyitself!
    Wewillcreateaquicktemperaturedifferencebetweenthesyringewithetherandthegaugesystem.
    Thatsthereasonwhyitsnotgoodideatocooldownthegaugesystembeforetherefill.
    Youwillneedtobuya52Cspraythatiswidelyusedtodebugthermalissuesinelectroniccircuit.(+/_9.9USD)
    SuchaspraycanbeorderedfromAmazonandlookslikethis:(typecoldsprayinthesearchbox)

    Method:
    Insertapieceofheatshrinkable(dia45mm)sleevearound
    thecapillarytermination,attheendofthebulb,thatwillbe
    usedtorefillthegauge.
    Removethesyringepiston.Wedontneedit.
    Insertthecapillaryterminationinthesyringeplasticneedle
    (noneedtousethemetalneedle).
    Thecapillarytubeshouldalmostperfectlyfitintothe
    syringe.

    Thenpositiontheheatshrinkablesleevetooverlapthecapillarytubeandthesyringetermination.
    Heatupthesleevetoshrinkit.Thiswillpreventtheetherfromleakingduringtherefillprocess.
    Theassemblyshouldlooklikeshownonpicture2+thesyringeattachedtothecapillaryterminationusedto
    refillthebulb.
    SorryIdidnottakeapictureduringtherefillprocess
    Positionthebulbandthesyringevertically.Itshouldlooklikethis:

    YvesYLG80Belgiumwww.aviplus.com


    Besuretoremovethegaugemetalcaninordertogetaccesstothebourdontubeinthegauge.(Theroundflat
    coppertube)
    Now,pourabout4mlofetherinthesyringeorsprayStartPilotdireclyintothesyringesothatyouhaveabout4
    mlofliquid.Youcaneasilyverifythatusingthesyringegraduations.
    Quicklytakethe52Csprayandsprayitdirectlyonthebulb,untilyouseetheetherbeingpumpedintothe
    bulb.Whiletheetherlevelinthesyringeisdecreasing,youwillseebubblescomingupinthesyringeandthe
    bulbwillbecomecompletelyfrozen.
    Etherispumpedintothebulbbecauseofthequickdecreaseinpressureduetotheverylowtemperatureinthe
    gaugebulb.ThisisexactlytheapplicationoftheBoyleandMariottewellknownrule.
    RefillagainthesyringewithetherorStartPilotinordertobesuretosaturatethesystemwithether.
    SprayagainthebulbANDthebourdontubewith52Ccoldspray.Youwillseethattheetherlevelinthesyringe
    willagainslightlydecreasebecausethecapillarytubeandthebourdonarebeingfilledupwithether.
    Thenquicklycrimpthecapillarytubeat2or3locationsbetweenthesyringeandthebulb.
    Idecidedalsotobendthecapillarytubeinordertoimprovethesealingbeforefinallysealingitwithtinsolder.

    Thatsit!Nottoodifficulttodo,isntit?Atleastlessthantofindthemethod.

    Finallyshortenthecapillarytube,ifitstoolong,andsealitwithtinsolder.
    Testyourgaugewithboilingwater.Itshouldindicateabout210F220F.

    Youcanslightlyajustthereadingbybendingthebourdontubeinthegauge.Compressingtheboudronspring
    willdicreasethereading.Ivereadsomewherethatyoucanadjustthereadingbetween5%and+5%.
    Mygaugereadingwascorrectaftertherefill.Iwilljustcheckthelinearitybutkeepinmindthatthis
    instrumentisamassproductiondevice,notalabmeasuringdevice.

    Feelfreetoreportyourexperiencewiththatmethod
    *******************
    YvesYLG80Belgiumwww.aviplus.com

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