Over countless revolutions, the little gear has a tendency to gradually walk
up the shaft.  I've found you can prevent it from doing this (if it isn't
broken) by putting a slight crimp in the shaft with a pair of sidecutters.
Doesn't take much of a crimp.

Karl Wolz
----- Original Message -----
From: "David Beierl" <dbeierl@IBM.NET>
To: <vanagon@GERRY.VANAGON.COM>
Sent: Saturday, April 01, 2000 11:27 AM
Subject: Re: Rebuilding Odometer- Fair Price?

> At 10:25 4/1/2000, John Andrew wrote:
> >scoured junkyards for these and all of them seemed to be cracked.  It
seems
> >to be quite a common problem.  Probably the combination of 20 year old
> >plastic and the sun beating down on the dash.  If anyone knows of a
source,
> >I need one for my 1980 Westy.  And I have tried the super glue trick.
>
> I suspect the combination of 20 year-old plastic and improper stress
> analysis by the plastics engineers at VDO -- though it's also been pointed
> out that resetting the odo while driving will cause problems if you hold
> your finger down.
>
> Worth a try:  take the best one you have, put some 90-minute epoxy (not
> filled stuff like JB Weld) inside and outside the cavity.  Place the gear
> and tightly wind one layer of sewing thread (cotton-polyester) or similar
> around the hub.  Paint on a little more epoxy if the thread isn't
> thoroughly saturated.  If this works, you won't be getting the gear off
> without destroying it, but I don't imagine that's an issue in this case
> (ten years ago my Dad fell in love with epoxy and has used it to secure
the
> most amazing things that I have had to later try to remove *without*
> destroying them.  Bah!).
>
> PS -- I don't know what the access is for string-winding with gear in
> place.  You can do it first and then install while epoxy still
> fluid.  You're going to have epoxied fingers; watch out for the gear teeth
> and wash thoroughly afterward.  I'd recommend a film of vaseline on the
> teeth just in case, but the glued portion has to be greaseless.  Brake
> cleaner will get the grease off but may attack the plastic, so keep it
away
> from the teeth.
>
> PPS -- now that I'm thinking in that direction, PVC plumbing cement may
> work.  If it does (try a touch of the primer to see if it makes the
plastic
> sticky -- if so you're good) you'll get a solvent-welded joint that's
> essentially one piece again.  Pressurize it by winding with thread as
> before, but maybe not so much tension.  Think this one through carefully
> before you do it -- the gear needs to be straight on the shaft etc, but
> still enough goop on the inside to grab.
>
> Steady hands help with all of this :)
>
> d
> David Beierl - Providence, RI
>   http://pws.prserv.net/synergy/Vanagon/
> '84 Westy "Dutiful Passage"
> '85 GL "Poor Relation"
>