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Step 4Prepare the Front of the Cartridge
Now the fun stuff.
First, it would behoove you to find a suitable workplace with proper ventillation. You will either be making some nasty plastic dust, or some death-fumes.
Take the front half and make two lines on the inside. The first line is directly down from the center of the cartridge's pull-tab area. The second line is directly horizontal with the little plastic support nub about halfway down.
Drill or create a 5/16" hole at the intersection of these two lines. If you don't want to be extremely accurate, make sure you err towards the bottom and away from the side. Vertical placement is much less important than horizontal... if you want the clock to line up in the textured area on the front. Be careful when drilling. Due to the thickness of the material, the drill bit will try to grab it (most likely). Stay in control and don't rush it. Clamps help immensely.
Now that you have a hole, you can insert the clock mechanism and find out that it won't fit. We'll have to cut out three things:
1) Remove the center screw mount. Completely. You might only need to take out half of it to fit the clock, but it's easier just to lop the whole thing off.
2) Remove the lower support boss.
3) Remove the tiny plastic pin directly below the cartridge pull-tab. Depending on your hole placement, you may not need to do this.
Unlike real surgical procedures, your boss-ectomies have no need for perfection. The resulting surface does not need to be flush because the clock has a little rubber pad that will hold it off of the surface slightly anyway.
Remove the washer and two nuts from the clock shaft and install the mechanism into the front of the cartridge. The mechanism and rubber washer should be behind the plastic and the washer and large nut should be in front of the plastic. Set aside the small round nut for now. It will be the final piece assembled on the completed clock. Check to make sure everything fits and then remove the clock mechanism. This may seem silly, but it'll save you time if you make sure it fits now.
The front (easy) half of the clock is now complete.
First, it would behoove you to find a suitable workplace with proper ventillation. You will either be making some nasty plastic dust, or some death-fumes.
Take the front half and make two lines on the inside. The first line is directly down from the center of the cartridge's pull-tab area. The second line is directly horizontal with the little plastic support nub about halfway down.
Drill or create a 5/16" hole at the intersection of these two lines. If you don't want to be extremely accurate, make sure you err towards the bottom and away from the side. Vertical placement is much less important than horizontal... if you want the clock to line up in the textured area on the front. Be careful when drilling. Due to the thickness of the material, the drill bit will try to grab it (most likely). Stay in control and don't rush it. Clamps help immensely.
Now that you have a hole, you can insert the clock mechanism and find out that it won't fit. We'll have to cut out three things:
1) Remove the center screw mount. Completely. You might only need to take out half of it to fit the clock, but it's easier just to lop the whole thing off.
2) Remove the lower support boss.
3) Remove the tiny plastic pin directly below the cartridge pull-tab. Depending on your hole placement, you may not need to do this.
Unlike real surgical procedures, your boss-ectomies have no need for perfection. The resulting surface does not need to be flush because the clock has a little rubber pad that will hold it off of the surface slightly anyway.
Remove the washer and two nuts from the clock shaft and install the mechanism into the front of the cartridge. The mechanism and rubber washer should be behind the plastic and the washer and large nut should be in front of the plastic. Set aside the small round nut for now. It will be the final piece assembled on the completed clock. Check to make sure everything fits and then remove the clock mechanism. This may seem silly, but it'll save you time if you make sure it fits now.
The front (easy) half of the clock is now complete.
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