Kondia FV-1 Head disassembly

[Mayhem]

Last week I was trying to get the very roughly machined feed trip lever (FTL) to fit and function.  One of the problems I found is that the hole drilled into the head where the reverse trip ball lever (RTBL) inserts is not accurate.  So, although the drawing for the micrometer screw gives the position of the hole, its location in relation to the slot into which the FTL sits is not parallel.

Ken noted that the drawing indicates "at assembly" for the hole and we did wonder about the consequences of drilling based upon the drawing.  My concern was the position of the hole in relation to the length of the screw, given the travel of the screw trips the lever.  The solution was to thin the FTL to allow rotation of the screw so that the RTBL would seat and function.

Given the need to pull the RTBL out and put it back in several times whilst filing the FTL, I made a special tool.
   

Something tells me that I am going to need this again.  Besides, I can never find a M3 screw when I need one...

The next task was to get the trip handle to actuate the cam rod.  I started by grinding the tip down and trying.  After several cycles, I noticed that the shoulders (where they had milled the flats that sit into the feed trip bracket) were rubbing on the feed trip bracket.  I extended these flats further down the trip handle with a hacksaw and a file.  The result was a fully functional lever that was a bit loose.  So, I welded a bit back onto the top and rounded it off.  It now feels better.  Sorry, no pictures.

With this done, it was time to attach the overload clutch trip lever to the overload clutch and fit this.  The drawing (see below) shows a plunger and spring (A).  However, there was no corresponding hole in the head at this position.  There was one at position B and given that the spring and plunger was missing, I have no Idea where they were.  
   

I looked at a picture from another Kondia that someone sent me and you can see the steel plunger where the drawing shows it to be.
   

You can see on my mill that there is no hole that corresponds with the drawing.
   
   

Hole B actually lines up with a notch on the arm, so I went ahead an used this.
   

It all seems to work as it should, although I have to read up on setting the tensions etc.

Actuated.
   

Tripped.
   

I have read that these early Kondia mills required a lot of "at assembly" work to get them functional, so I expected that a lot of parts simply wouldn't bolt straight on.  Whilst it is a long slow process, I am really enjoying the challenges and I'll know this thing inside out one I am finished.