Zybach Sample
Zybach Sample
Zybach Sample
Important:
McMaster Carr, a supplier whose part numbers are referenced throughout this document, can only ship within the
United States. Builders outside of the U.S. must find an alternate supplier for the required hardware.
Hardware part numbers and availability are subject to change. Verify that all hardware or equivalents are obtainable
prior to purchasing these plans.
Z yb ach
a mechanical clock
Contents
These plans include all the information required to build Zybach. They provide an outline of the build process, tips for an
accurate and successful build, lists of required tools and off-the-shelf components, a complete parts list, full scale patterns for
all plywood parts, and step-by-step assembly instructions.
Before Building
Read and understand all instructions before building. Failure to do so will lead to increased frustration levels, lengthened build
times, wasted material, and other vexing occurrences.
Build Process
Always wear eye protection and any other necessary personal protective gear. Read, understand, and abide by all
manufacturer instructions and warnings for all tools used.
1. Use a light duty/general purpose spray adhesive to temporarily bond the patterns to plywood. Apply the
adhesive evenly and sparingly.
2. Drill the holes first, and then cut out the parts. Hole alignment between parts is critical to proper function, so
care must be taken to drill the holes accurately. Take time to cut out the parts accurately. An accurately cut part
will require less sanding and less modification later.
3. Remove the patterns from the cut plywood parts, and then sand the parts to remove rough edges and any
residual adhesive.
4. Cut and tap all aluminum tubes, brass tubes, and stainless steel. See Plywood Thickness
Compensation in Tips + Tactics.
5. Following the assembly instructions, build all subassemblies and then the Top Level Assembly.
6. Cut the Main Weight based on the Weight of the Weight instructions in Tips + Tactics.
7. If desired, disassemble Zybach to finish its components. Note that stain and other finish options can
affect the thickness of parts and may also effect friction levels between moving parts.
Notes
When printing the patterns, always print at 100% scale. Do not use the “scale to fit page” option.
Zybach contains many moving wood parts as well as wood parts that stack onto one another. As such, using a quality, flat
Baltic birch plywood is very important. Cheaper, lower quality plywood, such as types often found at home improvement
stores like Home Depot, can be warped and knotted.
Changing humidity levels can cause wood parts to swell and move. Some binding or changes in performance may occur with
changes in humidity. As humidity levels return to normal, so too should the system’s performance.
Terms of Use
© 2016 Derek Hugger. All Rights Reserved.
By purchasing these plans, you have agreed to the following terms and conditions:
Reproduction of part or all of this document is prohibited except by the original retail purchaser for his or her own personal use. The contents of this
document and associated documents, including but not limited to instructions, designs, illustrations, diagrams, and patterns are for personal use, and may
not be included in any other work or publication, or be distributed, or be used for commercial purposes except with explicit written consent from the author.
Any apparatus or work created using the designs, patterns, or instructions in this document is for personal use only and may not be used for commercial
purposes nor sold for profit. The contents of this document are presented in good faith but without warranty and without guaranteed results.
phillips #1
brad point drill index
1/16” to 1/2”
in 1/64” increments
hex 5/64”
Supplies
taps 8-32*
scroll saw 1/4-20*
sandpaper
hacksaw
wood glue
spray adhesive
drill press clamps
monofilament
calipers (fishing line)
belt/disc sander
precision files
Recommended
(but not required)
drill
tube cutter
rotary tool
reamers
0.1280”, 0.2530”
Pattern Syntax
Patterns are labeled with a part name followed by a thickness dimension.
Example: Gear FG Spacer Thin is cut from 1/8” plywood. It also has a hole to be drilled thru with a 9/32” bit.
Gear FG
Spacer Thin 1/8
9/32
Dashed lines indicate a hole drilled from the side, centered on the thickness of the part.
Example: Hypocycloid Cam has a 9/64” hole drilled from the side. It also has a 1/4” thru hole drilled from the front.
1/4
Hypocycloid Cam 1/2
9/64
5/32
Ratchet Arm (back) 1/4
9/32
Wall Mounting
Use the Wall Mount Template as a guide for locating Zybach’s three mounting points on a wall. Mount into studs or use
appropriate anchors to ensure that Zybach will not fall or otherwise separate from the wall. The mounts must support
Zybach’s weight plus several additional pounds applied while winding.
Zybach should be mounted to a wall prior to completing the top level assembly. Mount the assembly any time between Top
Level Assembly Step 1 and Step 6.
As Zybach is weight driven, its height on the wall will directly impact its run time. For a 30 hour run time, drill Zybach’s
mounting holes such that the indicated line on the Wall Mount Template is 67” from the floor.
Ensure that the mounting screws fully engage the studs or anchors while maintaining a 3/8” gap from the wall to the head of
each screw.
3/8”
Weigh the jar of coins/BBs, and then weigh and measure the length of the 2” stainless steel cylinder.
The cut length of the cylinder to make the Main Weight = ( jar weight / cylinder weight ) * cylinder length
Note that when drilling and tapping the Main Weight, the hole must be centered. Any offset will cause the
Main Weight to hang at a slant.
Time Tuning
To adjust Zybach’s timing, adjust the Pendulum Weight and Thumb Screw. If the clock is running too quickly, slow it down by
moving the Pendulum Weight and Thumb Screw down. If the clock is running too slowly, speed it up by moving the
Pendulum Weight and Thumb Screw up. Note that very small changes in position can make a difference.
Down = Slower
Up = Faster
Once proper timing is achieved, tighten the Pendulum Weight and Thumb Screw against each other. This will help keep them
from lowering unintentionally over time.
Escapement Tuning
For optimal performance, a steady and even “tick tock” is desired. To adjust the timing of the escapement mechanism,
remove the Main Weight, slightly loosen the Set Screw in the Pallet Asm and adjust the angle of the Pallet relative to the
Pendulum Link Asm (see Top Level Assembly Step 6). Note that very small angle adjustments can result in large changes in
the escapement timing. Adjust the angle such that the timing between each “tick” and “tock” is as equal as possible.
Tick.......Tock.......Tick.......Tock.......Tick.......Tock
Tick...Tock.........Tick...Tock.........Tick...Tock.........
Tick..........Tock..Tick..........Tock..Tick..........Tock..
General Operation
To set the time, turn the Minute Hand clockwise or counterclockwise. Always let the Minute Hand drive the Hour Hand.
Never turn the hour hand directly, as doing so will damage the hypocycloid mechanism.
To wind Zybach, stop the Pendulum. Lift the Main Weight and gently pull down on the Wind Weight. Do not pull the Wind
Weight without lifting the Main Weight, as this can put undue stress on the components. Once wound, gently release the
Main Weight. Never allow the Main Weight to drop suddenly. Doing so will damage Zybach.
To start Zybach, gently push the Pendulum. Note that very little force is needed.
1/2” 3/16”
1/4” 7/8”
1/2” 3/8”
2x 0.03”
2.525”
3.838” 2x 0.20”
ID OD
OD outer diameter
ID inner diameter
L length
* Due to variations in plywood thicknesses, required tube lengths may vary slightly.
** Expand 0.120” tube ID with a #29 drill bit and then tap for 8-32 thread. Minimum thread depth: 1/2”.
*** Part numbers referenced are from www.mcmaster.com. © 2016 Derek Hugger
Metal
Weights
1/2”
Pendulum Weight
Ø2” Stainless Steel
Cut from cylinder used for Main Weight.
1/4”
1-1/2”
Wind Weight
Ø1/2” Stainless Steel
McMaster P/N: 8984K83
· Cobalt steel drill bits and taps are required for cutting stainless
steel. Standard bits and taps will not work well if at all.
· Weights may be made from steel or brass if desired.
· All holes must be perfectly centered. If holes are not drilled on
center, the weights will hang at a slant.
Main Weight
Ø2” Stainless Steel
McMaster P/N: 8984K57
Pendulum Ø3/8”
Pilot holes 9/64
Tap both sides for 8-32 thread.
46”
Pendulum Jig
Drill a 3/8” hole, 1.5” deep into 1/2” plywood.
Then, drill a 9/64” hole the rest of the way
through. Insert the Pendulum into the 3/8”
end, and use the 9/64” end to drill into the
Pendulum using a hand drill.
As dowels can split easily, it is not recommended to use untapped 9/64” holes like those used for set screws in the
plywood parts. Instead, drill the 9/64” holes and then tap both ends of the pendulum for an 8-32 thread. As tapping
wood will leave minimal diametric thread engagement, it is important to not overtighten the Pendulum’s mating parts.
The holes must be drilled centered and straight. If a lathe is not available for doing this, the above jig can be made to
help drill straight and centered holes in the pendulum.
1 2 3 4 5 6 in
1/4
Gear C 1/4
1-3/8
9/32
8x 1/16
Hypocycloid Gear B 1/4
1 2 3 4 5 6 in
2x 11/64
2x 11/64 1/16
1 2 3 4 5 6 in
1/16 9/32
Gear B 1/2 Gear F 1/2
1/4 9/32
Gear D 1/2
3x 1/16
9/64
Gear H 1/2
1/4 6x 5/64 3/16 5/64
9/
64
1/4
Fra
me
Su
pp
ort
1/2
1 2 3 4 5 6 in
1
7
Wind Wheel Asm
2
1 Ratchet Wheel 1x
3 2 Wind Wheel Large 3x
3 Wind Wheel Small 2x
4 Wind Wheel Spacer 1x
2
5 B Tube 9/32” x 1” 1x
3 6 Wind Cord 1x
Pallet Asm
1 Pallet 1x
2 Pallet Spacer 1x
5
5
5 1
6
4
3
tapped side
2
2 Frame Asm
5
2
5 5 6 1 Frame 1x
6
2 Frame Spacer 3x
tapped side 3 Bearing 1x
tapped side 4 Frame Support 1x
5 Screw #2 x 3/4” 6x
6 A Tube 1/4” x 2-1/2” 3x
6 5
Gear DE Asm
1 Gear D 1x
1 2 Gear E 1x
3 B Tube 9/32” x 3/4” 1x
4 Screw #2 x 1/2” 1x
4
3 2
3 7
6
Gear FG Asm
1 Gear F 1x
2 Gear FG Spacer Thick 1x
3 Gear G 1x
2 4 B Tube 9/32” x 1-1/2” 1x
1 5 Screw #2 x 3/4” 1x
6 Screw #2 x 1/2” 1x
7 7 Gear FG Spacer Thin 2x
4
5
Pendulum Asm
1 Pendulum 1x
2 Threaded Rod 1x
3 Pendulum Weight 1x
4 Thumb Nut 1x
7
6
1 Frame Asm 1x
2 Gear A Asm 1x
3 Wind Wheel Asm 1x
4 Gear FG Asm 1x
5 A Tube 1/4” x 4-1/8” 1x
6 Washer 1x
7 LSHCS 8-32 x 1/4” 1x
3
1
5
6
4
3
2
Feed the Wind Cord through the VSHCS and tie a knot.
Thread the VSHCS into the Wind Weight.