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Farmer John

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Reply with quote  #1 
I was impressed with the construction of this sm until I got to the plastic ZZ gear which had failed.  The 22 tooth plastic gear mates with a  steel gear on the main shaft, which provides motion to the ZZ.  The plastic gear which is the diameter of a nickel appears to have been pressed over the knurl of the cam shaft, leaving the plastic gear under constant stress.  I counted 8 incipient cracks in the gear,  (several visible in the pix) not including the one that caused failure.  This set-up was destined for failure.
     The mounting end of cam shaft is eccentric, to adjust the proper mesh of the gears.  The swing arm that oscillates via the cam shaft is mounted in two sets of ball bearings, one set on each side.  The dried up grease made the ball bearings feel as if square.  Cleaning and oiling restored smooth motion.   The ball bearings are visible in the 3rd pix.  To be continued.
100_2078.jpg 100_2079.jpg 100_2080.jpg 100_2081.jpg Farmer John

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WI Lori

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Reply with quote  #2 
John, can't wait to hear more!
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Lori in Wisconsin
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JonesHand52

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Reply with quote  #3 
RE Dressmaker 2000 broken zigzag cam - been there, done that. Good news is, there is a replacement part for a Kenmore that will fit and work just fine. 

https://www.ebay.com/itm/GEAR-ZIG-ZAG-WITH-CAM-10MM-SHAFT-JA36GJ-fits-KENMORE-148-12181-148-12190-/122464240742?hash=item1c83700466

Bad news is, after replacing the zz gear unit and getting it sewing like a champ in zigzag mode, it would not index properly when switching from ZZ to straight stitch. Nothing to do with the new part, but other adjustments need to be made to the end-loader zigag adjustment for the shuttle assembly. I didn't have time to get that figured out or scan through my library of sewing machine manuals so I just shelved the project for now. My wife has a higher model Dressmaker she likes better anyway - we just got this for a toy and to see what it was like. It will be adjusted and good to go I'm sure, just need to get it back on the bench, but my dance card is full and I have so many other projects lined up ahead of it. 

Anyway, you have the listing now for the part you need. The shaft doesn't fit down as low in the casting as the old part, but the set screw still does the job and you adjust it from the bottom with a screwdriver same as the old part. The Kenmore uses a metal gear, but I don't recall if it was steel like the listing illustration or bronze, but it's metal - not nylon. 

- Bruce
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Farmer John

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Reply with quote  #4 
A new bronze gear blank has been made along with a mandrel to hold the blank in the dividing head chuck (upper right).  The dividing head has been tipped upward to the helix angle of the teeth.  The lead is geared into the table screw. 
The crank handle (lower left)  is rotated one turn plus 27 holes in a 33 hole circle for cutting each tooth.  The gear ratio of the crank to chuck is 40:1.  The 2nd photo is of the instrument used to measure the tooth thickness at the  pitch diameter.  Dimensions have been taken from the old plastic gear.  About ready to cut teeth.
Farmer John
 100_2089a.jpg 100_2090a.jpg 

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pgf

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Reply with quote  #5 
Nice!!  
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ke6cvh

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Reply with quote  #6 
John,  that is amazing work.  I want to learn how to do this on our 4 axis CNC desktop mill once I can find the time.  BTW there are two versions of that gear as we already discussed in email but I'm mentioning for everyone else.  My Kenmore 158.1247 takes the same gear as yours but groove in opposite direction and part number same for Kenmore ending in an "S".  These gears are also used in Brother machines from the description.  Yours can be had for just under 15 dollars from an eBay seller in China called Kungpengsewing free shipping.  I've bought allot of parts from them and only once had a problem out of likely a couple dozen times when a folder arrived smashed.  It appears the other part is now out of production so I had to order out of USA after I ordered two of the gear you have.  Sounds like it's time to get a dressmaker like the one you are working on.....is everything else metal or other plastic drivetrain parts?  I've typically seen a plastic gear in the cam stack drive in about 1/3 of the older Kenmore machines and same for zig zag gear.  The other 2/3 seem to be all metal out of the collection we have in the drive train.  Our 1914's have a plastic piece in the beveled gear for the stitch selector which is not so critical to me.  Here is the link with the Kenmore part number attached..... our broken nylon gear looks sooo like yours except it is black instead of white.  It backed off the knurled piece and was causing the motor to be unable to turn the machine also.  Best regards, Mike I've been told many of the gears for the kenmore became unavailable about a year ago.  Link below to show the Kenmore part number:  https://www.ebay.com/itm/1PCS-3692-169-Zig-Zag-Cam-Gear-FIT-FOR-Kenmore-158-Series-sewing/153016574897?_trkparms=aid%3D111001%26algo%3DREC.SEED%26ao%3D1%26asc%3D20160908105057%26meid%3D2ba9cefab9f24eadaa65c636c7f2348d%26pid%3D100675%26rk%3D1%26rkt%3D15%26mehot%3Dnone%26sd%3D153016574897%26itm%3D153016574897%26pmt%3D1%26noa%3D1%26pg%3D2380057&_trksid=p2380057.c100675.m4236&_trkparms=pageci%3Afe23e04c-3f7c-11ea-91ef-74dbd180c637%7Cparentrq%3Add0dc9c616f0a489adc269aafffdeb9e%7Ciid%3A1 
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Farmer John

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Reply with quote  #7 
Life sometimes gets in the way of projects that I would rather be doing, but I got the tool bit ground and the 22 teeth cut in less than hour.  Just setting everything up took a lot longer.  I didn't blow the chips and brass dust off of the gear.  I will use Brownell's Accra-glas to cement the gear to the knurl, after a good de-greasing. 
Farmer John
100_2109.jpg 100_2112.jpg 

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ke6cvh

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Reply with quote  #8 
Amazing work Farmer John.  You are a true artisan.

Best regards,
Mike
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pgf

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Reply with quote  #9 
Fantastic!
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WI Lori

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Reply with quote  #10 
Very fine, Farmer John!
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Mavis

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Reply with quote  #11 
Well done, Farmer John.  Must be something good in Wisc. water.  Talent galore oozing out everywhere!
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Marla Gillum

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Reply with quote  #12 
Hi...I'm in need of this same part. Would you be interested in making me one? Price & shipping?
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Farmer John

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Reply with quote  #13 
Marla, I will try to respond gently.....While I can make most anything, and have the industrial tools and skills to do so, this kind of repair is done for my own satisfaction.  A machine shop will charge at least $80 per hour.  With multiple machine set-ups, tooling, labor and material, I doubt that a commercial shop could make this gear in 10 hours.  You do the math. 
     The gear is not available by itself.  It comes with the shaft and ZZ cam.  I modified the original shaft and used high strength epoxy to attach the new bronze gear.  I was quoted $37.50 for a replacement part plus $7.50 for shipping, but I have forgotten from whom.
These parts are available online, though I have no idea if they will fit your machine or mine, thus I elected to make the gear and repair the sm for a challenge.

https://www.ebay.com/itm/Sewing-Machine-Screw-Gear-For-Taiwan-Zig-Zag-Machine/160991484783?hash=item257bd71b6f:g:ZjoAAOxy9tpR7t3q

https://www.ebay.com/itm/1PCS-3692-169-Zig-Zag-Cam-Gear-FIT-FOR-Kenmore-158-Series-sewing/153016574897?_trkparms=aid%3D1110006%26algo%3DHOMESPLICE.SIM%26ao%3D1%26asc%3D20200520130048%26meid%3D509fdd6639b240549adcb7c9fcdb3ee8%26pid%3D100005%26rk%3D1%26rkt%3D12%26mehot%3Dpf%26sd%3D160991484783%26itm%3D153016574897%26pmt%3D1%26noa%3D0%26pg%3D2047675%26algv%3DSimplAMLv5PairwiseWebWithBBEV2bDemotion&_trksid=p2047675.c100005.m1851

Good luck with your Dressmaker.
Farmer John
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ke6cvh

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Reply with quote  #14 
Hello group,

  There are two of these zig zag gears...one is left and one is right.  One will work on the Dressmaker and one will work on Kenmore (I think different Kennies have different orientation so the dressmaker version works on at least one of the Kennies).  I ordered both types as I have two of the 158.1247's that take this part.  I also have a White that takes this part but cannot remember for certain only that it also has a plastic gear in it (pretty blue and white two tone but under the hood is the dreaded plastic part....but I am now remembering not a helical but a regular gear).  Basically, it seems, that one of the gears in this discussion  is still available and the other orientation is no longer available (or extremely hard to find in remaining new old stocks which is why I ordered an extra).  

  I've started to keep a file of which Kenmore 158 machines have solid metal gearing throughout and which ones have 1 or 2 plastic (like the zig zag gear but the rest metal).  We have just over 1 dozen 158 Kenmore machines here all 158's and if I ever buy any more I'll be certain to buy the 158's with 100 percent metal gearing.  

  Unfortunate that they would go to nylon at all in my opinion.  Nylon gears (and timing belts on engines) have always been a dread for owners as they are planned obsolescence IMHO.  At least with a chain it just stretches and jumps a tooth when shutting the engine off causing about 15 degrees off timing but no bent valves.  With nylon it ages and breaks.  Solid metal gearing is the best option (our two Isuzu c240 diesels...one in our hand made stainless jeep and the other in one of our 25kva gensets).  

  It is also sad they just don't make em like they used to when it comes to domestics.  One is almost forced into buying commercial machines if they want any durability or going all vintage.

Best regards,
Mike
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