Another Two Days Cleaning and Servicing
Alternating evenings in the garage. More cleaning, maintaining and measuring. Nice Zen time in the garage admiring the tools and recollecting how I got them and what projects they were used on.
Put a dent in the bottom tool chest. I love the Irwin Vice Grip plier sets and adjustable wrench sets. Their ergonomic grips are comfortable and grippy. Unfortunately this means they pick up dirt and oil like crazy. Fortunately they are really tough and scrubbing gets them clean again without any noticeably wear and tear on the handles. Go Blue and Yellow!
Here's a picture of one of the drawer liners after I pulled the tools out. The GearWrench tool chest doesn't seem to seal the drawers too well from dust and dirt. I make attach some weather strip solution to the bottom of the leading edge of the drawer and maybe on the chest on the left and right of the drawers.
While I've been doing the measuring I've also been taking a look at the efficiency of some of the blown cases the tools come in. Some are a complete waste of space like the GearWrench 81909 10 Piece Metric Crowfoot Wrench Set (that I moved to a 3/8" socket strip) and this Gearwrench KDT9570 Stubby Flex Gear SAE Wrench Set!
Others are fairly decent although they didn't really need to extra margins around the edges, like this GearWrench 81906 Flare Nut Metric Wrench Set.
One of my adventures was cleaning up and maintaining a CPS Products Pro-Set CPSWL132R Rechargeable 132 LED Underhood Work Light. I love this thing. It is in two parts - a light-saber tube with heavy duty rubberized ends and the expandable bracket that the tube clips into. Easy to move around and clips under the hood or trunk or under the car and rotates within the clips to point the light were you want it. Here's a pic:
There was a loose machine bolt and some light surface rust on the small machine nuts on one of the end pieces (which are indexed all the way around so the end hooks can grab in any direction) so I decided to, um, take it apart. We all know taking things apart is the easy part, right? There are four bolts on each end cap and three screws. I now know that the four bolts keep the end caps attached not only to the hollow tubes that expand out of the main housing... wait for it... but also the plastic dowels inserted in the hollow tubes that are attached to bungee cords that run all the way to the other end and are what keeps the end hooks holding on to stuff. Pull out one bolt - cool. Pull out the same bolt on the second tube - cool. Pull out the next bolt on the first tube - PWANG! Huh. Pull out the final bolt - PWANG! Pull the end cap off no problem and no evidence that anything is up. Savvy readers know this is because the bungees and the dowels are waaaaay down in there in the dark. Lift up the main housing of the bracket to clean it up and the hook on the other end starts sliding out. WTF? I grab it real quick but hear the sound of a tiny metal object hitting the floor - like tinker bell whispering in my ear that I'm screwed. I find two tiny metal dowels that look somewhat like infuriating watch band keepers. Turns out the hollow tubes fit within slightly larger tubes that have a slot cut into them along the entire length. Fitting the inner tubes into the outer tubes shows that the inner tubes have two tiny holes in them and these little buggers rest in these holes and are only held in place once the inner tubes are slid far enough in that they are parallel.
Wanted: 12 handed monkey to help assemble this device as follows:
1. Pull out the far end assembly so you can get to the bungees and their plastic dowels with two holes in each for the bolts.
2. Tie strings to each dowel, rout it through the main housing and out the other side while sliding the far end assembly into place. Pull the strings through the near end.
3. slide the two inner tubes from the near end over the strings and start them in the outer tubes within the main housing. After they are in about 1", rotate them around until the first set of holes are aligned with the slots of the outer tubes facing each other. With one hand hold the two inner tubes steady. With the other hand pick up the tiny watch band thingie (WBT) and position in between he two holes. With the gripping hand move the two inner tubes in while making them slightly more parallel so the WBT goes into both holes. With the fourth hand pick up the second WBT and repeat this process with the second holes while avoiding having the first WBT fall out. Insert the inner tubes the rest of the way without having the strings fall back down the tubes. Sigh.
4. Now it gets complicated. The near end assembly does not have any mechanism to hold the plastic dowels in the end of the assembly except the four bolts that also hold the inner tubes to the assembly. Said dowels are under tremendous tension trying to shoot back down the inner tube. Also, since the dowels fit tightly within the inner tubes the string will eventually be cut if too much pulling and pushing is done near the sharp end of the tube. This may or may not necessitate starting everything all over again to re-tie new strings. After trying for some time to conceive of a way to pull on something hidden within a tube while the end of the tube is covered with the end assembly I decided that the end assembly needed further disassembly! Of course! It all made perfect sense!

I could then use one hand to pull the two inner tubes out of the main assembly, my other hand to hold them down on the bottom half of the end assembly, my gripping hand to pull the strings and therefore the dowels on bungees to the end of the inner tubes while using my fourth hand to align the holes in the dowels with the holes in the inner tube and the holes in the end assembly (you still with me?) while my fifth, sixth, seventh, and eighth hands push the small machine bolts up through the end assembly thus easily holding everything together while my ninth hand lowers the top half of the end assembly with some help of my tenth hand aligning the four machine bolts. Voila! Just a walk in the park!
5. But first, it is necessary to chase the two steel ball bearings and tiny springs that will shoot out of the split end assembly as soon as the three screws are removed that hold it together. They are the indexing keys for the swiveling end hook. It all makes perfect sense except for the fact that these springs and ball bearings do not have keepers either. So, repeat step four while counteracting the pull of the bungees and use your eleventh and twelfth hands to hold down the sprung ball bearings as you clap on the top half of the assembly!
6. Until, you realize that you have to get the four tiny nuts started on the tiny bolts and the end assembly has tiny hexagonal indents to act as the nut stops. So back out each bolt from the high tension assembly but not so far as they let the dowel pull the bolt sideways down the tube. Drop in the tiny nut. Using a tiny male hex nut driver from underneath, without letting the other bolts drop onto the floor thus releasing the bungees (PWANG!) push the bolt up and engage the nut on the upper side. Repeat three more times.
7. Have anyone that helped murdered so that the secret of assembly, including the much valued 'how to not to assemble' knowledge, does not leave the room.
In any case, I was able to easily accomplish this on the first go in under five minutes. And no one is able to testify otherwise. Lesson learned - grow more hands.