Harken Ball Bearing Magic Box Repair

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Marcus
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Harken Ball Bearing Magic Box Repair

Post by Marcus » Wed Mar 08, 2006 1:51 pm

Just in case you're interested, I recently took apart my magic box to deal
with the cable which had jumped track from one to another pulley( no idea how this happened). Either way, it wasn't working right and no amount of pleading could persuade the cable to jump back to it's own side.

If you can afford to buy a new magic box, or actually have the tools to
swage the end on a new peice of cable, then do so. If you're a poor
college student like me, the following steps will help you get through this.

Step #1: Commit suicide. There is no way a living person can either enjoy or have the patience for this, so you might as well get death overwith. If you don't kill yourself now, the coronary you have during later steps will take care of this for you.

Step #2: Get the little jesus-clip off the top of the pin that all the
little pulleys are attached to. They're called jesus-clips because when
you try to remove one, they instantly develop the inertial energy of a
bullet and fly off into God knows where. When this happens you say,
"JESUS!" If you tap the top of the pin with a hammer (smack it actually)
the clip will pop off without you having to use one of those expensive
circlip pliers.

Step #3: Ease the pin out of the bottom of the assembly. Little ball
bearings will go everywhere. You might want to call these jesus-balls but
the imagery becomes uncomfortable.

Step #4: Quickly put the pin back in after you notice the ball bearings
going everywhere. Pick up as many as you can and swear a lot, like a
sailor if possible.

Step #5: Remove the magic box from the boat and take it inside, along with as many of the ball bearings as you found. Now is a good time to notice that it's called a Harken BALL BEARING magic box.

Note: the ball bearings are actually made of an unstable isotope as yet
undiscovered by scientists, but very familiar to boat people. When you
drop them, the velocity causes them to instantly disintigrate. The first
bounce is the actual impact, but the sound of the subsequent bounces is
actually the discorporation of the ball bearing.

Step #6: Take the pin back out, over a bowl this time. All the ball
bearings (minus the ones you lost) will fall out. I noticed some of mine
were cracked in half. Apparently this 'delrin' isn't as tough as they'd
like for us to believe.

Step #7: Get the old bike from the garage and pull the axle from the front
wheel. Get the bearings out. Throw them away. They're too big. This is
just practice.

Step #8: Tear the headset (the part that allows the forks to rotate) apart,
those bearings will be closer to the right size, if they're not, you're in
trouble. If the bike happens to belong to a child of yours, explain that
the boat is sick and needs an organ donation from the bike, and that you'll
fix the bike later.

Step #9: Ease the first pulley in. Make sure the proper wires are running
through the proper slots. Put the pin in to maintain the pulley in
position and put 13 little ball bearings back into the races. Cuss a lot
and drop a few. Cussing and yelling can induce the ball bearings to behave as you'd like. Remember, you've got extra bearings because of the bike's unselfish sacrifice, so you can lose a few more. If you do put metal bearings back in, try to alternate delrin/metal/delrin. If you don't have that many left, screw it.

Step #10: Lower the pin and put another pulley in. This will be about as
easy as putting a cat into a bag of water while trying to tie your shoes at
the same time due to the bent nature of wire. It can be done (putting a cat into a bag of water, that is). Once you have the wires lined up etc, the
pulleys width against the sides of the box will maintain the wires in their
tracks. This is the principle anyhow. If this had worked in the first
place you'd not be doing this now, would you? Put the pin back through.

Step #11: Insert 13 ball bearings into this pulley, cussing as appropriate.
Repeat 10 & 11 till all pulleys are in.

Step #12: Now you can admire your work and notice you've left a bit out
that goes on the BOTTOM. Scream and yell a lot. Start at 6 but remember to put the little washer on the bottom this time.

Step #13: Now that it's back together properly, go put it back on the boat.
After all is well, come back inside and take a nap. You'll need it
afterward, trust me.

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