Pantographs

[Ray Marinaccio]

In this thread I will demonstrate how I fabricated pantographs for a Pennline GG1.
The materials needed are:

.020" steel or brass wire
.010" brass sheet
1/2" length of 3/32" brass tubing
2 small springs


Materials for the jigs are:

a block of wood
straight pins
two 1/16" dia. roll pins (or 1/16" dia. rod)
1 popsicle stick


Tools needed:

needlenose pliers
fingernail clippers
soldering iron
solder
flux
small alligator clips
spring type clothes-pin
small file
ruler
pencil
scissors (to cut brass sheet)
tubing cutter (or razer saw)
1/16", 3/32", 1/8" drill bits and hand drill
small hammer
magnifier glass


This is a photo of the jigs

 

[Ray Marinaccio]

These are the dimentions for the jigs.
Jigs #1, #2, and #3 are made by driving straight pins into the wood at the possitions marked in the drawings and cutting off the heads.
Jig #4 is made by drilling four 1/16" holes at the dimentions shown and pressing 1/16" pins in the outer holes.
The drawing of jig #1 is backwards. Use the dimentions and build it as it is shown on the jig.

 

[Ray Marinaccio]

These are the dimentions for the collector parts and equalizer arms. Make two of each.

 

[Ray Marinaccio]

Once the jigs are constructed begin by forming a small hook on the end of a peice of .020" wire.

 

[Ray Marinaccio]

Then form it into a loop around one of the pins.

 

[Ray Marinaccio]

The loop should look similar to this.

 

[Ray Marinaccio]

Place the loop in jig #1 as shown with the arm on the left side of the bottom pin in the photo.
Then wrap it counterclockwise around the upper right pin.
Then counterclockwise around the upper left pin.

 

[Ray Marinaccio]

Remove it from the jig.
You will notice that it will spring out of shape. You will need to bend it a bit untill it fits easily onto the jig.
I don't cut the part from the wire untill this is done, it's easier to handle.

 

[Ray Marinaccio]

Once the part is cut from the wire I reinstall it on the jig and reshape the last loop.
This part will go on the left side of jig #5.
Two of these are required for each pantograph.

 

[Ray Marinaccio]

The next part will basicly be the opposite of the first.
Start by forming the first loop as before.
Place it into jig #1 with the arm on the righthand side of the bottom pin.
Wrap it clockwise on the upper right pin.
Then counterclockwise on the upper left pin.
Complete the part as you did with the first one.
This part will go on the right side of jig #5.
Two of these are required for each pantograph.

 

[Ray Marinaccio]

This is a comparison of the two.
Set these aside untill later.

 

[Ray Marinaccio]

Bend some wire around jig #2 as shown.
Four of these are required for each pantograph.

 

[Ray Marinaccio]

To form the mount brackets, Start by forming a loop on jig #3 as shown .

 

[Ray Marinaccio]

Then form another loop around the second pin.

 

[Ray Marinaccio]

Place the part into jig #4 as shown.

 

[Ray Marinaccio]

Form the loops on the ends as shown and cut the wires so they meet.
Two of these are required for each pantograph.
It is important that these two parts match perfectly.

 

[Ray Marinaccio]

Clamp the bracket to a popsicle stick and solder it together.
Try to get the solder to flow into all the gaps.
I found that adding a peice of wire as a filler and lots of flux helps.

 

[Ray Marinaccio]

Use a small file to remove the excess solder.

 

[Ray Marinaccio]

Form the lower cross braces as shown using jig #5 as a pattern.

 

[Ray Marinaccio]

The lower arm assembly will be fabricated in jig #5 by inserting two peices of wire through the arms fabricated earlier.
The equalizer lever of the arm on the left will be inserted into the hole in the jig.
The equalizer lever of the arm on the right will be pointing upward.
Use pins to hold the assembly in position.