Dip stick thread repair for a Volvo Penta DPS A drive on a boat in saxon wharf

Thread Repair for a volvo penta DPS A drive

Volvo Penta engine cover thread repair

We do a lot of thread repair work and have great success! this is a thread repair on a Volvo Penta DPS A drive engine cover plate.
Our customer regularly checks his oil level and the dip stick started to get a little stiff so they brought it in for us to have a look at it.

Thread Repair for a volvo penta DPS A drive

A volvo penta engine cover plate Top view

volvo penta DPS a drive engine cover plate

A volvo penta engine cover plate bottom view

Volvo penta Dipstick repair

The actual dipstick was fine

The thread was damaged, it doesn’t take much but a little dirt or debris can get into the thread and where it is an aluminum thread it can easily start to wear and get damaged.

volvo penta engine cover

fortunately they were able to bring it into our workshop and we could work on either side of the volvo penta engine cover.

a close up of the damaged thread on the Volvo enfging cover plate

here is a close up showing part of the damaged thread

Volvo penta thread fully repaired shown from the front

here is a close up of the finished repair

Volvo Penta Dipstick thread fully repaired shown from the back

here is a close up of the finished repair shown from the back

Dip stick for a volvo penta DPS A drive engine cover test fitted to makes sure all ok
All done thread repair on a engine head cover plate for a volvo penta DPS A drive

After the repair we test fitted the Dipstick to make sure it was fitting nice and smooth. Another happy customer!

We can have a look at yours if you like! distance no problem send it in the post

Where ever you are we can still look at yours.
Send us an email with some pictures in the first instance then if we feel we can fix we will advise a rough cost
All you need to do is pack it very well in a box with bubble wrap or good packing and send it signed for / recorded delivery.
When we receive it we will have a look and advise if we feel it is possible to fix or worth taking a chance.
If we send it back we will use your packaging supplied and we will send back by courier at our normal rate (we can advise this cost at the time once we know size and weight)
All being well we can inject a new lease of life into a part that you may of replaced a the cost a many hundreds  of pounds and most likly would also needed to use shims etc with he new part.

Please contact us with your project

Deep sea core drilling core removal tool

ROV core removal tool

ROV deep sea core drilling attachments

final batch of 12 ready for deployment
A batch of 12 core catchers for deep sea ROV core drilling

We were commissioned to manufacture a batch of 12 stainless steel core catchers for use by the national oceanography center on their Isis ROV. We were approached with the design concept and shown how it should work on the ROV but the big problem was that trials could only be done when doing the actual job at depth. There were some guesses as to what the material would be at the location but until the dive was done no one was really sure, for the initial prototype and our trials we were given a cinder block as it was the closest material that resembled what they had hoped to find.

Isis Deep Platform ROV
The Isis ROV deep sea platform

The Isis ROV is a lot bigger than it looks in the picture standing at over 8 feet tall it is packed with some very expensive and cool gadgets, inc HD and special cameras, special lighting to a titanium robotic arm!

ROV core removal tool
our initial trials with prototype in cinder block in use by hand applications

We needed to make a working proto type that had to be tested and approved by the client before the final batch of 12 were produced.
The cores were to be core drilled with a diamond core drill bit that would be driven by an underwater air driven motor held in one of the manipulator arms, but the issue was then retrieving the core sample after drilling as it was from deep sediment rock. The idea was to slip the core catcher over the core after drilling, then gently pull and wiggle it with the robotic arm manipulator, it would brake off whilst the teeth would dig in allowing it to be retained in the tube whilst it was removed from the rock bed.
We were given a cinder block as it was thought to be the closest material to the real stuff. 4 holes were cored so we could have a play.

first proto type gripper
the 1st prototype gripper
second proto type gripper
the 2nd prototype gripper
Third proto type gripper
the final protype gripper

We went through three design variations on the gripper before we got it working to how we thought it should work. We then presented it to the client for their own trials in their workshop with the ROV manipulator.

final batch of 12 ready for deployment
The finished assembled batch of 12 core catchers

The top T handles were T shaped as it is best for the robotic arm manipulator to grip onto and use, these were made so they could be unscrewed afterwards and removed so that the core could be slid out. The teeth dug into the core sample so it couldn’t fall our and the teeth were so good it was impossible to slide them the other way.
This was all machined, waterjet cut and welded in 316 grade stainless steel

final gripper design installed in the collection tube
a close up of the finished assembly showing the teeth on the gripper end
ROV core drill core remover in action
this is the view from the command room on the ship looking through the ROV cameras

You can see in this picture some of the camera views from the Isis ROV whilst at the bottom of the sea bed the two lower screens show the core catcher being deployed and in use at the bottom of the sea bed. The design worked perfectly!

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replacement gear wheel Waterjetcut and machined from aluminum

a close up of a waterjet cut gear cog

Urgent repair on auto pilot gear drive

Our customers yacht was having issues on their way over to the England and whilst they were temporarily berthed at Ocean Village in Southampton they had found a broken gear in their auto pilot system. They attempted a quick glue repair but weren’t confident in it as they had to set of to France in the morning so they asked us if we could make a new gear wheel. Which we did in good time so they could set sail on time.

broken plastic gear wheel
origonal broken gear
new aluminum gear wheel
new gear with slot feature
rear side of new gear

Some before and after pictures here show the gear wheel. You can click on them to see them closer up. The black plastic one has been marked up with red arrows indicating the split.
We had no drawings just the original part to use as a reference for dimensions. Once we extracted the data from the original part we created the cad data for the machines in our workshop.

a close up of a waterjet cut gear cog
a close up of the waterjet cut gear teeth

We waterjet cut the main gear teeth details then machined the slot and bore details on a CNC milling machine.

The gear wheel is quite small, shown here next to a penny for scale you can see the original plastic one and the new one plus a spare just in case!

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