Penguin Clock Assembly Drawings

THIRD ANGLE PROJECTION
Key
Note:
The clock parts are manufactured by CNC and the holes in the
parts are square to the part. The parts rely on a friction fit on
the shafts. If the shafts are not inserted carefully then the fit
may not be square. In this event the holes should be enlarged
slightly and the part reassembled on a jig as shown in Penguin0002.
The jig may not be required.
The assembly jig should be made from 19mm thick MDF or
plywood, cut to 200mm square. Three holes should be drilled
through in the centre of the jig as shown. It is very important
that these holes are drilled perfectly square to the jig body.
4 ,3 and
2 holes in the
centre of the jig.
200
An accurate pillar drill should be used for this purpose. If the

holes are not square then any parts assembled on the jig will
not be square and the clock may not operate.
The holes should be sized so that the shafts/tubes are held
firmly, but are still able to be removed by finger pressure.
200
UNLESS OTHERWISE SPECIFIED:

DIMENSIONS ARE IN MILLIMETERS
SURFACE FINISH:
TOLERANCES:
LINEAR:
ANGULAR:
NAME
DEBUR AND
BREAK SHARP
EDGES
FINISH:
SIGNATURE
Wooden Gear Clocks

316 Pickering Road, Hull, East Yorkshire, HU4 7AD.
Tel. 01482 509277
wooden-gear-clocks.co.uk
TITLE:
DATE
Assembly jig
DRAWN
CHK'D
MATERIAL:
Penguin-0001
MFG
Q.A
A4
DWG NO.
APPV'D
WEIGHT:
SCALE:1:2
SHEET 1 OF 1
Key
Note:
Parts should be assembled generally as
shown left, for the relevant shaft size.
The jig ensures that parts are
constructed square to the shafts.
Before use a small piece of masking
tape should be placed over the hole
area being used. This ensures that the
parts do not stick to the jig if surplus glue
squeeezes out.
The jig should be supported such that
the shafts have clearance below.
When removing parts from the jig push
the shaft from beneath so that the part is
not pulled from the shaft.

SURFACE FINISH:
TOLERANCES:
LINEAR:
ANGULAR:
NAME
DEBUR AND
BREAK SHARP
EDGES
FINISH:
SIGNATURE

Tel. 01482 509277
TITLE:
DATE
Assembly jig and 60 tooth wheel
DRAWN
CHK'D
Wooden Gear Clocks
MATERIAL:
Penguin-0002
MFG
Q.A
A4
DWG NO.
APPV'D
WEIGHT:
SCALE:1:2
SHEET 1 OF 1
Key
Glue to adjacent part and shaft
Glue to adjacent part only
Loose part
ITEM NO.
No.
No.
No.
PART NUMBER
Base top section
(penguin)
Base bottom section
(Penguin)
DESCRIPTION
QTY.
1
1
Note:
Apply masking tape to

this edge to prevent whte
adhesive staining the machined
edge if it squeezes out.
Apply white glue to this and

the adjoining face.
Apply masking tape to

this edge to prevent whte
adhesive staining the machined
edge if it squeezes out.

SURFACE FINISH:
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BREAK SHARP
EDGES
FINISH:
SIGNATURE
Before gluing the 2 halves of the base together,

stick masking tape to the edges as shown. This
ensures that white glue does not stain the
machined edges of the base sections if it
squeezes onto them. The stains do not readily
show until you start surface treatment, so it is best
to avoid the possibility of stains.
Apply a generous amount of white glue to both
surfaces such that it squeezes from the joint on
the application of pressure. This ensures that the
glued joint does not have any dry spots which
can show up after surface treatment.
After positioning the two halves together, check
that the hole for the battery box is aligned on
both sections. Do not worry if the edges are not
aligned as these can be sanded flush when
finishing.
Apply pressure either with clamps or a large
weight, spread with boards to ensure even
pressure. When dry scrape excess glue form all
the joints, including the battery box recess. If the
battery box holes are not aligned then it may be
difficult to insert the battery box.
Remove the masking tape and finish as per the
instructions.
Set aside.
Wooden Gear Clocks

Tel. 01482 509277
TITLE:
DATE
Penguin base sub assembly
DRAWN
CHK'D
MATERIAL:
APPV'D
Penguin-0003
MFG
Q.A
A4
DWG NO.
WEIGHT:
SCALE:1:5
SHEET 1 OF 1
Key
Loose part
ITEM NO.
1
2
No.
No.
No.
2
PART NUMBER
frame
Bearings 623
Ensure that the bearings have been degreased as per the

instructions and dried off.
Before final finishing of the frame as per the instructions, file the
radius as shown until the frame fits flush into the base. Do a trial fit of
the frame into the base. The frame should slide in easily but still
remain in position once fitted. If it is too tight remove a small amount
of MDF from the frame as shown.
Finish the frame to the required standard and set aside to dry for
about 24 hours (depending on temperature).
With a small amount of rolled up abrasive paper (about 120 grade)
sand the bearing holes to remove dried finishing products until the
bearings can be pushed into the holes using thumb pressure only.
The bearings should just be tight enough to stay in place.
When happy that all the bearings fit as above, place a small
amount of white glue into the bearing holes on each side. Slide a
bearing over one of the prepared shafts and insert through the
hole. Slide a bearing on the other side as shown in section G-G.
Push the bearings into each hole squarely using a flat edge. The
shaft will act as a guide. Push each one a small amount at a time
whilst rotating the shaft.
SECTION K-K
SCALE 1 : 3
Bearings should
be flush with
face.
SECTION G-G
SCALE 1 : 3
QTY.
1
10
Note:
DESCRIPTION
Check that the shaft rotates freely. There should be no perceptable

resistance. Check that the bearing is flush with the frame as section
K-K. Gentle remove the shaft without disturbing the bearings.
Repeat the procedure from the other bearing holes and set aside to
dry.
Should you require to remove a bearing, then using a small flat
screwdriver, push from the opposite side through the opposite
bearing hole applying force to the outer race only.
Remove MDF from this
face if fit too tight
File radiused corners until

frame fits flush in base

SURFACE FINISH:
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ANGULAR:
NAME
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EDGES
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Tel. 01482 509277
TITLE:
DATE
DRAWN
CHK'D
Wooden Gear Clocks
MATERIAL:
Frame sub assembly

Penguin-0004
MFG
Q.A
A4
DWG NO.
APPV'D
WEIGHT:
SCALE:1:5
SHEET 1 OF 1
ITEM
PART NUMBER
NO.
1 Battery holder
Key
5
8
3
Ensure that wires
are soldered in the upward
orientation as shown
Base sub assembly_Penguin
3
4
5
6
Base Cover_Penguin
Wood Screws
Self adhesive felt pad
Electrical wiring
DESCRIPTION
QTY.
1
Penguin-0003
red 7/0.2 x 100mm long
1
4
4
1
10 Switch
11 Connectors
1
11
6
Switch is inserted from

the other side
Exploded view
2
10
Assembled view
Note:
A towel or similar should be layed out to work on for this procedure. This will minimise the chances of
scratching the finished base.
Trial fit the battery box and switch. The battery box should be a tight fit and go to the bottom of the hole. The
switch should be thumb pressure only. Apply force to the outside edge only, not the rocker button as it may
damage it. Remove the battery box and switch. Refer to drawing Penguin-0025 for wire lengths.
Solder a red wire and a black wire to the battery box ensuring the orientation is as shown. Press the battery
box into place.
Solder two red wires to the switch and insert into the base as described above.
Route the wires along the appropriate channel. Masking tape helps keep the wires in the channel.
Connect the wires to the connector block as shown and insert into the round hole.
Four pads should be attached to the finished cover as shown and the cover screwed into place.
Trial fit the 6mm conduit into the 6mm hole in the base. Remove and set aside.
Wooden Gear Clocks

Tel. 01482 509277
TITLE:
DWG NO.
SCALE:1:5
Base assembly
Base assembly-Penguin-0005
SHEET 1 OF 1
A4
Key
Loose part
ITEM
PART NUMBER
NO.
1 Base assembly_Penguin
No.
No.
No.
Frame sub assembly
Wiring conduit
DESCRIPTION
QTY.
Penguin-0005
Penguin-0004
6mmOD brass tube x 150 lg
Note:
Apply white glue to the sides of the rectangular slot in

the base. Slide the frame into the hole until flush with
the surface of the hole. Ensure that the dimension of
267mm shown in the drawing is adhered to.
Fit the brass conduit tube into the frame. The hole may
need adjustment to get a push fit.
Remove any excess glue with a damp cloth and set
aside to dry.
267

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EDGES
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Tel. 01482 509277
TITLE:
DATE
Frame assembly-Penguin
DRAWN
CHK'D
MATERIAL:
Penguin-0006
MFG
Q.A
A4
DWG NO.
APPV'D
WEIGHT:
SCALE:1:5
SHEET 1 OF 1
Key
Loose part
ITEM
NO.
1
2
3
4
5
6
7
No.
No.
No.
PART NUMBER
escape wheel
10mm diameter blank
10mm x 3mm diameter spacer
Escape wheel shaft
3
M3 washer
8 tooth wheel
2mm internal diameter O ring
3
3
QTY.
1
1
4
x 50 long brass rod(from 150 length) 1
2
1
1
Note:
The escape wheel should have already been
sanded smooth at this stage. Carefully radius the
trailing edge of the teeth as shown, ensuring that
you do not reduce the overall diameter of the
wheel. The faces of the escape wheel provide a
rotational force to the escapement, therefore
they need to be sanded very smooth (1000
grade) or the friction will be excessive and the
clock will not run.
2
6
DESCRIPTION
Carefully tap the escape wheel shaft squarely

through the hole in the escape wheel until
approximately 12mm is protruding as shown.
Ensure that the escape wheel orientation is
correct.
Check for squareness by fitting shaft to the clock
frame and turning. A maximum of 3mm of
movement at the edge should be allowed. Refer
to drawings Penguin-0001 and 0002 to remedy.
Glue the 4 spacers and 8 tooth gear wheel into
place with white glue. Check that the shaft is not
protruding beyond the 8 tooth wheel as this
would make it impossible to glue the blank into
place. If it is then tap it down until flush.
Glue the blank into place.
SECTION G-G
SCALE 1 : 1
12
The trailing corner of each

tooth should be sanded to
a radius. This gives clearance to
the exit pallet.

SURFACE FINISH:
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LINEAR:
ANGULAR:
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DEBUR AND
BREAK SHARP
EDGES
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Wooden Gear Clocks

Tel. 01482 509277
TITLE:
DATE
DRAWN
CHK'D
MATERIAL:
A4
DWG NO.
APPV'D
Penguin-0008
MFG
Q.A
Escape wheel assembly
WEIGHT:
SCALE:1:2
SHEET 1 OF 1
Key
Loose part
ITEM
PART NUMBER
NO.
1 60 tooth wheel
2 M3 washer
3 10mm x 3mm diameter spacer
4 8 tooth wheel
No.
No.
No.
1
DESCRIPTION/DRAWING
60 tooth wheel shaft
x 68 long brass rod(from 300

length)
QTY.
1
2
12
1
1
Note:
Apply a small amount of white glue to the end of the shaft and
carefully tap the shaft squarely into the 60 tooth wheel until flush.
Check for squareness by fitting shaft to the clock frame and turning. A
maximum of 3mm of movement at the edge should be allowed.
Refer to drawings Penguin-0001 and 0002 to remedy.
Glue the remaining six spacers (red) into place with white glue. Set
aside to dry.
3 3 3 3 3 3 5
3 3
3 3 3
The 8 tooth wheel and spacers needs to be removable from the shaft
so should not be glued to the shaft.
Check the fit of the 8 tooth wheel on the shaft. If it is too tight to be
pushed on by hand then relieve the hole slightly with a 3mm drill. Tap
the drill bit into the hole, then whilst holding the drill bit with a pair of
pliers, turn the wheel a small amount and then remove. Repeat the
procedure until the wheel can be pushed onto the shaft by hand
whilst still retaining a good friction fit. Repeat for the spacers also as
these may be tight.
The following is assembled in the opposite way as it is shown on the

shaft, but is fitted as shown.
Push the 8 tooth wheel onto the shaft so that approximately 20mm is
protruding. Glue the 6 spacers into place using white glue. Try to
avoid getting too much glue onto the shaft as the assembly needs to
be removed. Set aside for about 10 minutes then pull the assembly
from the shaft by pulling on the 8 tooth wheel. Set aside to dry and
clean the shaft with a damp cloth to remove any glue residue.
SECTION G-G
SCALE 1 : 1.5
G

SURFACE FINISH:
TOLERANCES:
LINEAR:
ANGULAR:
NAME
DEBUR AND
BREAK SHARP
EDGES
FINISH:
SIGNATURE
Wooden Gear Clocks

Tel. 01482 509277
TITLE:
DATE
60 tooth wheel assembly
DRAWN
CHK'D
MATERIAL:
Penguin-0009
MFG
Q.A
A4
DWG NO.
APPV'D
WEIGHT:
SCALE:1:2
SHEET 1 OF 1
Key
Loose part
ITEM NO.
No.
No.
No.
PART NUMBER
2
3
30 tooth wheel
M3 washer
10mm x 3mm
diameter spacer
8 tooth wheel
4
5
QTY.
1
1
2
11
1
Note:
Apply a small amount of white glue to the end of the shaft and
carefully tap the shaft squarely into the 30 tooth wheel until flush.
Check for squareness by fitting shaft to the clock frame and turning.
A maximum of 3mm of movement at the edge should be allowed.
Refer to drawings Penguin-0001 and 0002 to remedy.
Glue the remaining two spacers (red) into place with white glue. Set
aside to dry.
2
5
4 4 4 4
4 4 4
The 8 tooth wheel and spacers needs to be removable from the

shaft so should not be glued to the shaft.
Check the fit of the 8 tooth wheel on the shaft. If it is too tight to be
pushed on by hand then relieve the hole slightly with a 3mm drill.
Tap the drill bit into the hole, then whilst holding the drill bit with a
pair of pliers, turn the wheel a small amount and then remove.
Repeat the procedure until the wheel can be pushed onto the shaft
by hand whilst still retaining a good friction fit. Repeat for the
spacers also as these may be tight.
The following is assembled in the opposite way as it is shown on the
shaft, but is fitted as shown.
Push the 8 tooth wheel onto the shaft so that approximately 36mm is
protruding. Glue the 9 spacers into place using white glue. Try to
avoid getting too much glue onto the shaft as the assembly needs
to be removed. Set aside for about 10 minutes then pull the
assembly from the shaft by pulling on the 8 tooth wheel. Set aside to
dry and clean the shaft with a damp cloth to remove any glue
residue.
Four of the spacers are left loose so as not to apply excessive friction
to the assembly. This makes assembly more manageable.
SECTION G-G
SCALE 1 : 1
G
DESCRIPTION
length)
Do not put glue

in this joint
SURFACE FINISH:
TOLERANCES:
LINEAR:
ANGULAR:
NAME
DEBUR AND
BREAK SHARP
EDGES
FINISH:
SIGNATURE
Wooden Gear Clocks

Tel. 01482 509277
TITLE:
DATE
DRAWN
CHK'D
MATERIAL:
A4
DWG NO.
APPV'D
Penguin-0010
MFG
Q.A
30 tooth wheel assembly-Penguin
WEIGHT:
SCALE:1:2
SHEET 1 OF 1
Key
Loose part
ITEM NO.
No.
No.
No.
Cannon tube
2
3
32 tooth wheel
Hour hand
10mm x 4mm
diameter spacer
4
15
G
3
PART NUMBER
4
4
NAME
1
1
4
Carefully tap the cannon tube squarely into the 32 tooth wheel
(with a small piece of wood) leaving approximately 9mm
protruding.Put a small amount of white glue on the tube just
below the 32 tooth wheel and tap the tube through until 15mm is
protruding as shown in the drawing. This ensures that excessive
glue does not cover the tube.
Check the wheel for squareness by fitting to the clock frame
(over a shaft). The edge of the wheel should not deviate by more
than 3mm. If it does then refer to drawings Penguin-0001 and
0002 for remedy.
Set aside to dry.
Glue 2 spacers in place adjacent to the 32 tooth wheel ensuring
that no glue remains on the visible tube. Set aside to dry.
DEBUR AND
BREAK SHARP
EDGES
FINISH:
SIGNATURE
Slide the hour hand over the tube. This part is held in place by the
friction of the spacers either side. It is required to move for setting
the clock but should be tight.
This is achieved by gluing the next two spacers firmly into place
and pushed up to the hour hand.
Put a small amount of white glue in the hole of the first spacer
(not the tube) and slide down the tube until it is flush with the
hour hand. Apply a small amount of white glue to this spacer
and the tube. Slide the last spacer in to place firmly. This process
of assembly is designed to stop glue getting on to the hour hand
and gluing it to the shaft.
Apply a load to the last spacer with masking tape/ rubber band
or similar means.
Set aside to dry.
SECTION G-G
SCALE 1 : 1

SURFACE FINISH:
TOLERANCES:
LINEAR:
ANGULAR:
QTY.
Note:
2
2
DESCRIPTION
4 OD x 3 ID x 50 long brass tube (
from length)
Wooden Gear Clocks

Tel. 01482 509277
TITLE:
DATE
Hour hand assembly
DRAWN
CHK'D
MATERIAL:
Penguin-0011
MFG
Q.A
A4
DWG NO.
APPV'D
WEIGHT:
SCALE:1:2
SHEET 1 OF 1
Key
Loose part
ITEM NO.
No.
No.
No.
PART NUMBER
Minute hand O ring
enclosure
2mm internal
diameter O ring
Minute hand O ring
enclosure blank
Minute hand
DESCRIPTION
QTY.
2
Assembly retainer
3
1
1
Note:
Slide the O rings over one of the 3mm diameter shafts. Slide
one of the O ring enclosures over one of the O rings. Apply a
small amount of white glue to the second O ring enclosure
and slide this over the O rings. The enclosures may require
twisting as they are pushed together to overcome the O ring
elasticity.
Apply a small amount of white glue to the minute hand and
slide this into place. Check that the hand is square to the shaft
and adjust if necessary.
Set aside to dry.
Remove the shaft by pulling in the direction of the minute
hand. This ensures that the O rings remain in the enclosure.
Apply a small amount of white glue to the blank and position
as shown. Set aside to dry.
The minute hand and the blank have a slightly burnt side.
Ensure these are fitted so this doesn't show.
2
G
SECTION G-G
SURFACE FINISH:
TOLERANCES:
LINEAR:
ANGULAR:
NAME
DEBUR AND
BREAK SHARP
EDGES
FINISH:
SIGNATURE
Wooden Gear Clocks

Tel. 01482 509277
TITLE:
DATE
Minute hand assembly
DRAWN
CHK'D
MATERIAL:
Penguin-0012
MFG
Q.A
A4
DWG NO.
APPV'D
WEIGHT:
SCALE:1:1
SHEET 1 OF 1
Key
Loose part
ITEM
PART NUMBER
NO.
1 10 tooth wheel
2 M3 washer
No.
No.
No.
G
6
DESCRIPTION/DRAWING
3
64 tooth wheel
5
6

minute hand assembly
2
1
1
Note:
20

length)
QTY.
1
1
4
1
Round both ends of the shaft.
Penguin-0012
Carefully tap the shaft squarely into the 64

tooth wheel until 20mm protrudes as show.
Check the wheel for squareness by fitting to
the clock frame and rotating. The edge of the
wheel should not deviate by more than 3mm.
If it does then refer to drawings Colossus-0001
and 0002 for remedy.
Glue two spacers into position as shown in the
drawing.
Carefully tap the shaft squarely into the 10
tooth wheel and glue into place as shown,
followed by two further spacers.
Set aside to dry.
SECTION G-G
SCALE 1 : 1.5

SURFACE FINISH:
TOLERANCES:
LINEAR:
ANGULAR:
NAME
DEBUR AND
BREAK SHARP
EDGES
FINISH:
SIGNATURE

Tel. 01482 509277
TITLE:
DATE
DRAWN
CHK'D
Wooden Gear Clocks
MATERIAL:
Penguin-013
MFG
Q.A
A4
DWG NO.
APPV'D
WEIGHT:
SCALE:1:5
SHEET 1 OF 1
Key
Glue to adjacent part and shaft No. Glue to adjacent part only
10
Loose part
No.
ITEM
PART NUMBER
NO.
1 bottom bob weight
No.
3
2
P
M3 x 100 long brass rod
Top bob weight
Pendulum shaft
5
6
7
8
9
10
10mm diameter blank

M3 washer
Pendulum frame
M3 brass dome headed nut
6 6 4
DETAIL P
SCALE 2 : 3
5
Assembly retainer
1
1
1
2
2
1
1
1
Fit the bottom bob weight into position as shown

and retain with a small amount of epoxy at the
rear.
Screw the top bob weight fully to the bottom
initially and fit the top dome nut.
Set aside to cure.

SURFACE FINISH:
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ANGULAR:
NAME
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BREAK SHARP
EDGES
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Wooden Gear Clocks

Tel. 01482 509277
TITLE:
DATE
Pendulum shaft/Escapement assembly
DRAWN
CHK'D
MATERIAL:
DWG NO.
APPV'D
7 7
x 37 long brass rod

(from 150 length)
Put a small amount of epoxy resin in the slot for the

brass M3 rod as shown.
Push the M3 rod into the slot from the side with a
small screw driver. Ensure that it is straight and
parallel to the pendulum top. Set aside to cure.
Carefully tap the pendulum shaft squarely into the
pedulum frame until flush. Ensure the pendulum is in
the correct orientation as shown. Check that the
pendulum is square to the shaft. If it's not then refer
to drawings Pendulum-0001 and 0002 to remedy.
Glue the spacers and blank into place with white
glue and set aside to dry.
SECTION N-N
SCALE 1 : 3
QTY.
1
Note:
Apply a small amount of epoxy

to keep in place.
Cut fron length

supplied
DESCRIPTION
A4
Penguin-0014
MFG
Q.A
WEIGHT:
SCALE:1:5
SHEET 1 OF 1
Key
Loose part
ITEM NO.
No.
1
2
No.
No.
PART NUMBER
remontoire
counterbalance side
2 pence piece
remontoire
counterbalance pin
DESCRIPTION
QTY.
2mm dia brass rod x 11 long(cut

from length)
2
4
1
Note:
Using epoxy resin glue two coins to one of

the sides and allow to cure.
Using epoxy resin glue the second side to
the coins and insert the uncut length of
2mm rod through both sides for alignment
whilst curing.
When cured, cut the 2mm rod to length
and insert as shown with a small amount of
epoxy. Use epoxy to glue the remaining two
coins to the sides.
Set aside to cure.
2
1
2
2

SURFACE FINISH:
TOLERANCES:
LINEAR:
ANGULAR:
NAME
DEBUR AND
BREAK SHARP
EDGES
FINISH:
SIGNATURE
Wooden Gear Clocks

Tel. 01482 509277
TITLE:
DATE
DRAWN
CHK'D
MATERIAL:
A4
DWG NO.
Pendulum-0015
APPV'D
MFG
Q.A
Remontoire counterbalance
WEIGHT:
SCALE:1:1
SHEET 1 OF 1
Key
Loose part
ITEM NO.
1
No.
No.
No.
PART NUMBER
Face
Dowels 9 x 58mm
long
DESCRIPTION
QTY.
1
Cut from lengths supplied
Note:
Sand the end of the dowels until they fit snugly into both
the relevant holes in the face and the holes in the clock
frame.
Put a small amount of wood glue into the relevant holes
of the face and tap the dowels in until fully home. Fit
the assembly to the clock frame. This ensures that the
dowels are in the correct positions. Do not glue the
dowels into the frame. A friction fit is all that is required.
Set aside to dry.

SURFACE FINISH:
TOLERANCES:
LINEAR:
ANGULAR:
NAME
DEBUR AND
BREAK SHARP
EDGES
FINISH:
SIGNATURE
Wooden Gear Clocks

Tel. 01482 509277
TITLE:
DATE
Face assembly
DRAWN
CHK'D
MATERIAL:
Penguin-0016
MFG
Q.A
A4
DWG NO.
APPV'D
WEIGHT:
SCALE:1:5
SHEET 1 OF 1
Key
Loose part
ITEM
PART NUMBER
NO.
1 Motor bracket spacer
No.
No.
No.
1
DESCRIPTION
QTY.
1
2
3
mercury switch holder

motor mounting counterbalance bracket
2
1
Wood Screws
motor mounting bracket
Note:
Glue items 1, 2 (2 off) and 5 together with white glue. Use a piece of 3mm
rod for alignment and ensure that screw holes are aligned. A cocktail stick
or similar can be used to aligh screw holes.
Set aside to dry
Screw item 3 to the assembly using the two wood screws provided.
Set aside.
2
2
4
3

SURFACE FINISH:
TOLERANCES:
LINEAR:
ANGULAR:
NAME
DEBUR AND
BREAK SHARP
EDGES
FINISH:
SIGNATURE
Wooden Gear Clocks

Tel. 01482 509277
TITLE:
DATE
Motor bracket sub assembly
DRAWN
CHK'D
MATERIAL:
Penguin-0017
MFG
Q.A
A4
DWG NO.
APPV'D
WEIGHT:
SCALE:1:2
SHEET 1 OF 2

SURFACE FINISH:
TOLERANCES:
LINEAR:
ANGULAR:
NAME
DEBUR AND
BREAK SHARP
EDGES
FINISH:
SIGNATURE
Wooden Gear Clocks

Tel. 01482 509277
TITLE:
DATE
Motor bracket assembly
DRAWN
CHK'D
MATERIAL:
DWG NO.
APPV'D
A4
Penguin-0017
MFG
Q.A
WEIGHT:
SCALE:1:2
SHEET 2 OF 2
Key
No.

Loose part
ITEM
PART NUMBER
NO.
1 M3 x 8 screw
2 6v motor
3 10 tooth motor wheel
4 Motor bracket assembly
5 2mm internal diameter O ring
6 Mercury switch
No.
No.
DESCRIPTION
Penguin-0017
Assembly retainer
heat shrink
QTY.
2
1
1
1
1
1
1
Note:
This assembly should be completed with the required wiring as per the next
drawing (Penguin-0018 sheet 2 of 2), although the wiring is not shown on
this drawing for the sake of clarity. The wiring schematic Penguin-0025
should also be refered to.
Cut 1 piece of red wire 380mm long, 1 red piece of wire 140mm long and 1
black piece of wire 460mm long.
Cut the terminals on the mercury switch to approximately 10mm long and
solder the two red wires to the terminals. Heat shrink the insulation to the
shorter length, making sure that it covers all exposed wiring. Set aside.
Remove the 2 screws from the motor bracket sub assembly and remove
the counterweight bracket.
Attach the motor to the bracket using the 2 screws provided and attach
the 10 tooth wheel to the motor. Apply a small amount of eopoxy to the
motor shaft if the wheel is a loose fit. Ensure that the wheel does not touch
the screws.
Using 'Blue tack, plastercine or similar, fit the mercury switch into the
housing as shown.
Thread the short red wire through hole 1 so that it can be soldered to the
motor terminal. Thread the long red wire through hole 2 so that it can be
threaded down the wiring conduit. Thread the black wire through hole 1
and hole 2 so that one end can be soldered to the motor and the other
threaded down the conduit. Reattach the counterweight bracket.
Solder the red and black wires to the correct motor terminals. The red wire
can be trimmed to minimise the amount of slack before soldering. The
black wire should be pulled through to minimise slack.
Set aside
Hole 1
Hole 2
DETAIL G
SCALE 2 : 1.5

SURFACE FINISH:
TOLERANCES:
LINEAR:
ANGULAR:
NAME
DEBUR AND
BREAK SHARP
EDGES
FINISH:
SIGNATURE
Wooden Gear Clocks

Tel. 01482 509277
TITLE:
DATE
DRAWN
CHK'D
MATERIAL:
A4
DWG NO.
APPV'D
Penguin-0018
MFG
Q.A
WEIGHT:
SCALE:1:2
SHEET 1 OF 2
Key

SURFACE FINISH:
TOLERANCES:
LINEAR:
ANGULAR:
NAME
DEBUR AND
BREAK SHARP
EDGES
FINISH:
SIGNATURE
Wooden Gear Clocks

Tel. 01482 509277
TITLE:
DATE
Penguin motor bracket assembly
DRAWN
CHK'D
MATERIAL:
DWG NO.
APPV'D
A4
Penguin-0018
MFG
Q.A
WEIGHT:
SCALE:1:2
SHEET 2 OF 2
Key
10
6
8
ITEM
NO.
1
2
3
4
5
6
7
8
9
10
PART NUMBER
Hour hand assembly
Face assembly
Frame assembly
remontoire counterbalance
Pendulum shaft assembly
DRAWING
Penguin-0011
Penguin-0016
Penguin-0008
Penguin-0009
Penguin-0010
Penguin-0006
Penguin-0018
Penguin-0013
Penguin-0015
Penguin-0014
QTY.
1
1
1
1
1
1
1
1
1
1
Wooden Gear Clocks

Tel. 01482 509277
TITLE:
Penguin clock assembly exploded
A4
DWG NO.
Penguin-0020
SCALE:1:10
SHEET 1 OF 2
Note: Assemby
Note: Setting up
At this point all assemblies should be completed and all wheel

assemblies should fit easily into the relevant bearings.
Set the top bob weight as low as possibe. This makes the clock
run easier. Adjustments can be made to this when the clock is
running.
The escape wheel assembly should be fitted first to the frame assembly.
Ensure that a washer is fitted adjacent to both bearings and that the
2mm O ring is fitted to prevent movement. Approximately 1mm of end
float (side to side movement) should exist.
Give the pendulum a gentle push. If the escape wheel teeth

tips have been sanded enough as indicated in the drawing
Penguin-0008, then the pendulum should swing and the
escape wheel rotate. If the exit pallet (right hand side) catches
on any of the escape wheel teeth then slightly more needs
removing from the back of that tooth. A small flat file can be
used for this purpose. Do not remove material from the end of
the tooth.
When the clock is running, pay attention to the escapement
pallets. If they do not appear to be running evenly then a small
weight may need to be stuck to the rear of the pendulum
frame. It will probably look as if one of the pallets is struggling to
clear the escape wheel, whilst the other clears easily.
Next fit the 60 tooth wheel assembly as above.

At this point check that the two wheels are free to rotate. You should be
able to blow on the escape wheel and the assembly should spin freely,
stopping at random positions. If it does not spin freely and/or it does not
stop at random positions, then sanding of the wheels is probably
required.
The 30 tooth wheel should be fitted next as above, followed by the 64
tooth wheel and a rotation check.
Fit the face assembly.
Although the frame is symetrical, it can still be out of balance

due to differing densities in the plywood and uneven mounting
surface.
Next fit the hour hand assembly. Check that this rotates freely on the
shaft before meshing with the 8 tooth gear. If it doesn't then the tube
probably needs deburring on the inside diameter. Fit the minute hand
and check that about 1-2mm of end float exists on the hour hand
assembly when the minute hand is pressed fully home.
I usually use a small piece of 'blue-tack' for this purpose.

I usually allow the clock to run fast initially for about 1 day
before adjusting the top bob weight (regulating).
If all the wheels have been sanded with 1000 grade and the
clock will still not run, then apply graphite to the 8 tooth wheels
using a soft graphit pencil.
Check the rotation by blowing on the escape wheel.

If all appears well then the pendulum can be fitted as per the gear
wheels.
The bob weight should be about 20mm from the top of the
frame to give an approximate setting.
At this point you can slide the remontoire assembly onto the 64 tooth
wheel shaft, in the horizontal position. Do not worry about completing
the wiring at this point. The clock will run for a minute or so under the
weight of the motor and disassembly is easier.

SURFACE FINISH:
TOLERANCES:
LINEAR:
ANGULAR:
NAME
If the clock runs fast then the bob weight needs to be screwed
anticlockwise when viewed from the top. If the clock runs slow
the the reverse applies.
DEBUR AND
BREAK SHARP
EDGES
FINISH:
SIGNATURE

Tel. 01482 509277
TITLE:
DATE
DRAWN
CHK'D
Wooden Gear Clocks
MATERIAL:
Penguin clock assembly exploded

Penguin-0020
MFG
Q.A
A4
DWG NO.
APPV'D
WEIGHT:
SCALE:1:10
SHEET 2 OF 2
ITEM
NO.
1
2
3
4
5
6
7
8
9
10
10 4
PART NUMBER
DESCRIPTION
QTY.
remontoire counterbalance
Hour hand assembly
Face assembly
Frame assembly
Pendulum shaft assembly
Penguin-0015
Penguin-0011
Penguin-0016
Penguin-0008
Penguin-0009
Penguin-0010
Penguin-0006
Penguin-0018
Penguin-0013
Penguin-0014
1
1
1
1
1
1
1
1
1
1
2
6

SURFACE FINISH:
TOLERANCES:
LINEAR:
ANGULAR:
NAME
DEBUR AND
BREAK SHARP
EDGES
FINISH:
SIGNATURE
Wooden Gear Clocks

Tel. 01482 509277
TITLE:
DATE
DRAWN
CHK'D
MATERIAL:
A4
DWG NO.
Penguin-0021
APPV'D
MFG
Q.A
Penguin Clock Assembly
WEIGHT:
SCALE:1:10
SHEET 1 OF 2
Parts list - Penguin clock

ITEM
NO.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
45
46
47
48
49
50
51
52
57
58
PART NUMBER
frame
Base top section (penguin)
Base bottom section (Penguin)
Base Cover_Penguin
Face
64 tooth wheel
60 tooth wheel
30 tooth wheel
32 tooth wheel
escape wheel
10 tooth wheel
8 tooth wheel
Pendulum frame
Escape wheel shaft
Pendulum shaft
Cannon tube
M3 x 100 long brass rod
Dowels 9 x 58mm long
remontoire counterbalance pin
Wiring conduit
Hour hand
Minute hand
Minute hand O ring enclosure
Minute hand O ring enclosure blank
bottom bob weight
Top bob weight
10mm diameter blank
M3 washer
Bearings 623
Wood Screws
remontoire counterbalance side
2 pence piece
Self adhesive felt pad
Battery holder
Switch
6v motor
M3 x 8 screw
10 tooth motor wheel
Mercury switch
Connectors
heat shrink
Red wire
Black wire
Motor bracket spacer
mercury switch holder
mounting counterbalance
59 motor
bracket
60 motor mounting bracket
61 M3 brass dome headed nut
DESCRIPTION
QTY.
1
1
1
1
1
1
1
1
1
1
1
3
1
1
3 x 126 long brass rod(from 300 length)
1
1
1
3 x 37 long brass rod (from 150 length)
1
4 OD x 3 ID x 50 long brass tube ( from length) 1
Cut fron length supplied
1
Cut from lengths supplied
2
2mm dia brass rod x 11 long(cut from length) 1
6mmOD brass tube x 150 lg
1
1
1
2
1
1
1
2
33
9
10
4
6
Assembly retainer
6
2
4
4
1
1
1
2
1
1
1
1
7 x 0.2 x 820mm long
1
7 x 0.2 x 560mm long
1
1
2
1
1
1
100mm long
100mm long
Negative
100mm long
Connector
100mm long
Positive
460mm long
Switch
Battery holder
140mm long
380mm long
Motor-wire to rotate anticlockwise

when viewed from shaft end
Mercury switch
Note:
All wire lengths are approximate. These lengths may
be reduced depending on your soldering/routing
skills.

SURFACE FINISH:
TOLERANCES:
LINEAR:
ANGULAR:
NAME
DEBUR AND
BREAK SHARP
EDGES
FINISH:
SIGNATURE
Wooden Gear Clocks

Tel. 01482 509277
TITLE:
DATE
DRAWN
CHK'D
MATERIAL:
A4
DWG NO.
APPV'D
Penguin-0025
MFG
Q.A
Wiring schematic
WEIGHT:
SCALE:1:1
SHEET 1 OF 1

Penguin Clock Assembly Drawings

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Penguin Clock Assembly Drawings

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THIRD ANGLE PROJECTION

An accurate pillar drill should be used for this purpose. If the

UNLESS OTHERWISE SPECIFIED:

Wooden Gear Clocks

THIRD ANGLE PROJECTION

UNLESS OTHERWISE SPECIFIED:

316 Pickering Road, Hull, East Yorkshire, HU4 7AD.

Assembly jig and 60 tooth wheel

Wooden Gear Clocks

THIRD ANGLE PROJECTION

Apply masking tape to

Apply white glue to this and

Apply masking tape to

UNLESS OTHERWISE SPECIFIED:

Before gluing the 2 halves of the base together,

Wooden Gear Clocks

Penguin base sub assembly

THIRD ANGLE PROJECTION

Ensure that the bearings have been degreased as per the

Check that the shaft rotates freely. There should be no perceptable

File radiused corners until

UNLESS OTHERWISE SPECIFIED:

316 Pickering Road, Hull, East Yorkshire, HU4 7AD.

Wooden Gear Clocks

Frame sub assembly

THIRD ANGLE PROJECTION

Base sub assembly_Penguin

red 7/0.2 x 100mm long

Switch is inserted from

Wooden Gear Clocks

THIRD ANGLE PROJECTION

Frame sub assembly

6mmOD brass tube x 150 lg

Apply white glue to the sides of the rectangular slot in

UNLESS OTHERWISE SPECIFIED:

Wooden Gear Clocks

THIRD ANGLE PROJECTION

Carefully tap the escape wheel shaft squarely

The trailing corner of each

UNLESS OTHERWISE SPECIFIED:

Wooden Gear Clocks

Escape wheel assembly

THIRD ANGLE PROJECTION

60 tooth wheel shaft

x 68 long brass rod(from 300

The following is assembled in the opposite way as it is shown on the

UNLESS OTHERWISE SPECIFIED:

Wooden Gear Clocks

60 tooth wheel assembly

THIRD ANGLE PROJECTION

30 tooth wheel shaft

The 8 tooth wheel and spacers needs to be removable from the

Do not put glue

Wooden Gear Clocks

30 tooth wheel assembly-Penguin

THIRD ANGLE PROJECTION

UNLESS OTHERWISE SPECIFIED:

Wooden Gear Clocks

Hour hand assembly

THIRD ANGLE PROJECTION

Wooden Gear Clocks

Minute hand assembly

THIRD ANGLE PROJECTION

64 tooth wheel shaft