Bonney Addiction said I needed a 3/4 Ratchet, so...

divercal · Jun 7, 2017

Bonney Addiction said I needed a 3/4 Ratchet, so... **for update see Sept 10 post**

One showed up on Ebay recently... A Bonney 4292 Zenel 3/4 Square Drive.
The Seller clearly stated - “..is in very good condition”. And then says “It is in smooth working order”.
I won the auction and of course after receiving it found it was not in "very good condition" nor was it in "smooth working order". It looked ok from the outside but it barely turned and when it did it was jerky and would lock up. same in the other direction when you fiddled with it enough to select the other direction it would turn loosely and sometimes lock up or would catch then slip to free spin.
Taking it apart I see the problem, It has numerous Chipped and gnarled teeth. Enough to cause the erratic behavior.
After getting over myself for trusting ebay, I decided to keep it and see if I couldn't get it working properly.
Any ideas on repairing the chipped ratchet drive and selector teeth?
I am thinking of having a welder build up the teeth and then file down to the ideal profile.
Also since I drove the Rivets out - any ideas of Re-Riveting it or possible re securing the cover plates with Counter Sunk Barrel Bolts....?

bonneyman · Jun 7, 2017

First off, nice find.

Second thought - you do have to be real careful with ebay.

Third, I've seen photos where guys would weld the top of broken teeth and then grind/file them down to pyramids again. Actually saw this process in a 1940's book on welding. And your ratchet is probably from those days. So, it is possible.

Good luck.

woody 73 · Jun 7, 2017

Very nice... :beer:

Maybe you could try placing a looking for in the wanted section of the GJ, you never know if some other member has some spare parts needing a good home.

Roberts210 · Jun 8, 2017

Without some serious, dedicated work that's going to be useless. I'd send it back, or ask for a return of my money through Paypal. I've sold a lot of tools on ebay. Sellers like that need to be stopped.

tym · Jun 8, 2017

Roberts210 said:
Without some serious, dedicated work that's going to be useless. I'd send it back, or ask for a return of my money through Paypal. I've sold a lot of tools on ebay. Sellers like that need to be stopped.

Agreed. Whether you decide to keep the ratchet or not, the seller was deceptive, and needs to get dinged for it by eBay.

divercal · Jun 8, 2017

Thanks for the replies guys...
Ya I agree any repair probably won't stand up to ********* use but it might..My use of it would be infrequent for crankshaft/transmission sprocket nuts on my bikes if I use it. I'll post again if I get the teeth welded and reshaped. I've seen similar repairs to gear teeth on the web.

Username already in use · Jun 8, 2017

Sorry I bid you up, but now I'm glad you ended up with it instead of me... :sad:

I would also send it back. That's a shame, it looked like a nice one.

divercal · Jun 8, 2017

No worries thats the ebay marketplace...

r_olson_06 · Jun 10, 2017

I was thinking of bidding on that ratchet. Too bad it is messed up. Those don't come around often.

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Sunset_Z28 · Jun 10, 2017

I've got one of those and wondered what the inside looked like, but I was scared of knocking the rivets out. So thanks for that!

bsg1 · Jun 12, 2017

i'd send it back. your patience and tenacity will bring another to your table.

divercal · Sep 10, 2017

SPOILER ALERT!!! I fixed the ratchet but had to modify it....
So as you have read from my original post I paid a price for trusting an ebay seller. Ended up with a very defective Bonney Ratchet. So after considering my options I decided to keep it and try to fix it.
I fixed it and am happy with the results - I did have to modify it to achieve my design intent. After having the worst broken gear teeth re welded with TiG Welds and filing them to a close profile - The issue was trying to Re-use the original rivets or make new rivets and try to "permanently" close up the works of the ratchet until it crapped out again or design an Assembly kit that would close up the ratchet and allow for future maintenance of the gears as necessary. I opted for the latter and it turned out great - at least for me. I did have to drill and countersink the 2 plates considerably so for you Purists out there- Sorry 'bout that but I didn't see an alternative and to tell you the truth I think its an improvement on the original design.
I ended up using the Barrel Bolt concept. Problem is its difficult to find large barrel bolts - So I made my own. The 2 top barrel bolts 10-24 screw thread type were available - but i couldn't find any for a 3/8 - 1/4-20 size. I made my own out of 3/8 socket head machine screws. I had to drill them out and tap for the 1/4-20 screws. I also had to ream out the 4 larger holes in the ratchet to accommodate the new larger 3/8 bolts.

divercal · Sep 10, 2017

more pics

Chillylulu · Sep 10, 2017

You saved it.

Chilly

zktk01 · Sep 10, 2017

Nice work.

thehorse13 · Sep 10, 2017

Looks great. Fingers crossed for you that it holds up to normal use.

tym · Sep 10, 2017

Very nice. I really like your barrel bolt solution!

r_olson_06 · Sep 10, 2017

Re: Bonney Addiction said I needed a 3/4 Ratchet, so... **for update see Sept 10 post

Impressive work. Did you shape the tooth profile with a file or something else after the welding?

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woody 73 · Sep 10, 2017

Good job it looks well done! :thumbup:

PFSard · Sep 10, 2017

Sorry to hear about the eBay fiasco. Nice work!!! Hope this works out for you. If I had seen that amount of damage, I would not even have realized that there were any hope of repair.

divercal · Sep 10, 2017

Chilly , zktk01 - Thanks!

TheHorse13 - Thanks - yeah I would have rather the Welder ground down the teeth more and layered up more weld passes.....if the welds chip out that's what I will request next time - but who knows tig welds might be super strong......

tym , woody73 Thanks!! ya I struggled with the Rivet replacement idea...somebody tried to "Stake" one of the rivets before (see one of the pics) and I didn't want to end up with more of that...I thought of recessed Socket head cap screws (counterbored) but wanted a "Flush" solution - thats when I dreamed up the idea of using counter sunk flatheads. Took alot of work (2 broken taps, 1 broken tap remover ...LOL...) plus drilling out small holes into larger holes doesn't work well (ask me how I learned that...) so I used a couple Adjustable Hand Reamers to enlarge the 4 holes to 3/8.

r olson 06 - Correct I hand filed the welds to as close to the profile to the other teeth...as one may notice the file job isn't perfect but I was trying to remove as little of the weld beads as possible to leave as much on the gear as possible....

PFSARD...hahaha.. I'm stubborn beyond reason alot of the times....and dream up ideas that require alot of work and frustration but sometimes work out. I'm glad I stuck with it. I didn't want to drill and grind on the tool but couldn't think of any other reasonable solution.

Lookin4'67Galaxieconv · Sep 10, 2017

Great job! :thumbup:

bonneyman · Sep 11, 2017

The Bonneyman is impressed....and in awe! :rocker:

Freaking awesome job - I would not hesitate to show that ratchet off.

twertsy · Sep 11, 2017

Great job saving that ratchet!

divercal · Sep 11, 2017

thanks Lookin467Galaxieconv, bonnyman and twertsy - ya no matter what It still says Bonney on the handle with all the scratches, dings and obvious hard use of the former owners (s). Its an American made tool that is built to last (um..except for maybe the gear teeth).

Come to ponder about it the cause of the gear teeth being so chowdered up may be in the hardness of the steel of the two outer plates. the gear unit protrudes through and is held in the center of the head by two 1" holes in top and bottom plates. these holes are now enlarged, due to original clearance plus wear of the gear head spinning and torque applied, to some measurable amount over the diameter of the gear head protrusion.
I was going to have the welder run a couple beads around the large hole of both top and bottom plates and then file or ream to just a hair larger diameter than the gear head protrusion...but will maybe confront that beast later if needed.

Bonney Addiction said I needed a 3/4 Ratchet, so...

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