Repair and Restoration Archives - Donald's Innovations & Repairs

1923-Era National Cash Register Restoration

Donald Dawson — Mon, 16 Mar 2026 15:25:12 +0000

BACKSTORY

This 103-year-old, 1923-era National Cash Register 852-e spent many years in a Vancouver plumbing store owned by my client’s family. He kept it for about 36 years before choosing to restore it.

My client asked me to do my best to make it resemble how he remembered it. It didn’t need to be perfectly functional, and as you will see, some things, like getting a perfect printout of a receipt, were not possible.

This model is electromechanical and can operate either by motor or manual cranking. The serial number has an S prefix, indicating it was returned to Toronto for service and was resold to my client’s family’s Vancouver plumbing store after 1940.

big project, many pictures

Repairing and restoring this cash register was complex and long. Before-and-after pictures hopefully capture the scope of the work involved. Enjoy!

condition of the cash register

It required a lot of research and time to identify the best steps for cleaning, unjamming the mechanism, and operating this machine. From my research, I discovered that this model was the hardest to restore. Finding parts for it was nearly impossible.

It required a thorough cleaning, an electrical overhaul, and the replacement of the display glass and the special milk-glass coin plate.

One side of the register was missing its motor shield, so I eventually fabricated a new one.

Documenting every screw, lever, and key was essential, using photos and diagrams to identify their locations.

Some of the mechanical linkages were jammed.

The ten-cent coin key was not engaging the gears.

Though the cash register looked as if it were made of wood because the woodgrain appeared so realistic, the body was actually constructed from sheet steel with a woodgrain finish applied to the metal.

It would require some research to replicate the original finish.

cleaning the keys and nameplate

To clean the keys, I had to use a steel dental pick. Cleaning each key face was a long, tedious task because there was so much grime and finger grease in the center, around the perimeter, in the grooves, and along the outer edges of the keys. I then polished the stainless-steel escutcheons that surrounded the keys.

The cash register had a nameplate displaying the workers’ names and lettered keys corresponding to those names, all of which needed cleaning.

fabrication of the motor casing

The motor was missing its protective cover and required a new one to be fabricated.

There was an angle brace around the interior of the casing to reinforce the adjoining side and edge pieces. I silver-soldered the angle brace to the interior of the casing.

Holding the motor casing to the machine required low-profile latches. These latches had to be thin enough to fit within the casing's interior and were not commercially available, so I fabricated the correct latch style to secure the casing.

The seams of the motor casing needed bronze TIG brazing for reinforcement.

Eventually, I blended and ground the casing edges, and I painted a faux woodgrain finish.

Fabrication of MACHINE RESET KEYS

Originally, six keys were used to reset different functions. My client only had one key. From this, I gauged the size of the other keys I needed to make. I searched online for keys specific to this model, but finding the right ones felt like searching for a needle in a haystack.

I tried to buy them from the U.S., but I couldn’t be sure they would be the correct keys for the model. As it turned out, the ones I found online weren't the correct ones, just by comparing the length and cut of the keys to the one I had.

Since I’m not a locksmith, making these keys was quite tricky, even with my machinist skills.

I found pictures of these keys, printed them to scale, and traced the designs onto steel to make new reset keys. For one of them, I had no picture and had to improvise.

fabrication of the handle knob

Securing the rotating manual crank handle on the register required a brass threaded knob. Though I didn’t have a source or picture to tell me what the knob should really look like, I created one that would serve the purpose.

glass coin plate

The cash register’s milk-glass coin plate tested the coins for authenticity. If the coins shattered when the clerk hit them on the glass plate, they were fakes. Milk-glass is no longer sold commercially and is very costly to reproduce. I developed a method to imitate the newer version of this glass using standard glass, painting the edges and underside white to prevent scratching the paint when used for its original purpose.

Originally, this cash register had a central hole for mounting the milk-glass. However, a central hole in the new glass would have shattered the glass coin plate. Instead, I added newly fabricated corner brackets painted to match the wood and glass.

receipt tape mechanism

The correct size of bond paper for the receipt tape was unavailable. A modern machine requires a 2 1/4" wide tape, so I had to cut the rolls to 1 5/16" wide and smooth the edges. Threading the tape through the machine, so it could cut and dispense a receipt, was challenging.

The printed receipt tape in the picture is nearly legible. This is the best I could do to restore this part of the cash register.

Eventually, the cashier tape housing unit got a clean interior base coat paint.

cash drawer

As soon as the cash register keys were pressed, the cash drawer, which barely opened when the machine arrived, burst open vigorously after I adjusted the springs and the drawer guide rail. I also made new rubber grips for the cash drawer to keep currency bills in place.

restoration of the woodgrain finish

I sanded the motor case to prepare it for the eventual woodgrain finish.

To achieve the woodgrain effect, I applied layers of pigment in different colours and used texturing techniques to closely mimic the woodgrain pattern.

The motor case and cashier tape housing received a coat of red oxide primer to maintain a clean appearance.

A clear wax polish was applied to make this register shine.

touch-up paint

I touched up the arrow and numerals with paint, as well as in areas that were heavily scuffed.

fuses and power cord

Since this is an electromechanical machine that requires a motor fuse, I had to replace it. I tested different amperages to find the best one for the motor. Fuses were hard to find, but I sourced them locally.

It all boiled down to cleaning and lubricating the cash register to ensure it operated safely without jamming, and to protect the motor.

The cloth sheath on the original power cord had worn out and needed replacing. The goal was to ensure that the electrical system complied with the BC Electrical Code.

A project of this scope deserved the time and space it took to tell its story and assemble photos of this saga.

If you’ve read this far, bravo!

Miriam - The Blacksmith's Writerly Wife

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Horse Weathervane Restoration

Donald Dawson — Fri, 26 Sep 2025 17:40:00 +0000

An 1880 horse weathervane was in for restoration and repair. Unlike most of my weathervane repairs, this horse would not be going back onto a roof. The owner wanted it mounted onto a base so he could showcase it on a mantlepiece.

Click Here For Client Video

Materials

Rebar tie wire
Silver solder
Copper
Acrylic paints
Acid etchants

Processes

Silver soldering
Bending and cutting
Forming

damage

The horse was split in many different areas and tied together with wire at various points. It needed a lot of work. Its tail was broken off, one ear was missing, the main swivel column leg was missing a knee, the hoof required fixing, and the mane was fragile, splitting and breaking into pieces. Additionally, numerous perforations in the body needed to be filled. Lastly, the horse needed a new swivel pole to attach to the base.

A wasp nest inside the horse

One never knows what one will find with a restoration. The big surprise was finding a wasp nest from nose to tail tip and down the legs within all the cavities of the horse. And it was a heavy nest! This wasp nest factored in splitting the horse apart. Freezing rain also would have expanded the metal.

Once I split the horse open and pulled it apart, I removed the wasp nest to clean it thoroughly inside and out. Residual wasp and nest biomatter were still present, so a hot bath and some compressed air finished the task.

Below the two images of the wasp nest and the opening of the cavity, you can see the unique hammers I use to get into tight areas.

SOLDERING THE HORSE TOGETHER

By cleaning and etching the copper edges to a bright finish, I prepared the surfaces for soft soldering. I patched and sealed holes and all broken edges with soft solder, ensuring that I retained and mimicked as much of the original patina in the repaired areas.

Rebuilding the parts

I used soft solder to add muscular detail to the front leg and to build up the broken cast-iron ear.

The copper cone on the front leg helped me form muscular detail. I then created a kneecap for the leg that wrapped around a pivot post.

Next, the leg and tail were soldered and the body sealed from the ingress of wasps and other debris.

final stage

Once the horse was sealed, I had to dress the solder by grinding, rasping, rough filing, profiling, scraping, sanding, and polishing the soldered joints in preparation for working on the patina.

I created a new pigment and patina colouring using various chemicals and acrylic paint. Finally, I mounted the leg for this beautiful horse to revolve around. The weathervane was finally complete and ready for many more years of enjoyment.

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Moroccan Lamp

Donald Dawson — Sat, 05 Apr 2025 16:14:58 +0000

This treasured Moroccan lamp needed repair and an overall clean-up. It had many dents, a crushed finial, missing hooks and missing glass ornaments.

Materials

Brass
Stained glass
Copper foil

Processes

Soft-soldering
Removing creases/ straightening
Cleaning

The finial

A crushed cone-shaped finial was at the bottom of the lamp. The pictures here show the extent of the damage.

To create a new finial, I flattened the original, drew a paper pattern, and transferred the pattern to 28-gauge brass.

I rolled the finial into a cone, soldered the ends together, and attached the cone to the bottom of the lamp.

In order to remove the creases in the lamp, I had to make a forming tool.

Crushed finial

Repaired finial

Flattened finial for drawing

Recreating the finial pattern

GLass ornaments

I rebuilt the glass ornaments from stained glass and copper foil.

To complete the dangling blue diamond shape, I cut the glass to fit the space and adhered copper foil, which was soldered to make the copper foil rigid. In order to hang the glass diamond properly, I added a tiny brass bead to the tip of the diamond shape on the copper foil.

Below you can see those glass ornaments and the finished lamp.

Glass ornaments replaced and hung

Forming tool to remove creases and bends in the metal

hooks

I made copper hooks and soft-soldered them in place from which to hang the dangling, coloured glass ornaments. You can see this process in this brief video.

A bit of background on moroccan lamps

These hanging lamps are intricately designed lighting fixtures that create a warm, inviting atmosphere, reflecting Morocco's rich artistic heritage. Often made from brass with colourful stained-glass panels or pierced metalwork, they cast mesmerizing geometric patterns, shadows, and light effects on walls and ceilings. Crafted using traditional techniques passed down through generations, these lamps add exotic elegance to any space.

Unique colours and shadows of Moroccan lamps

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1960s Russian Tin Toy Car

Donald Dawson — Tue, 28 Jan 2025 16:37:19 +0000

This Russian 1960s tin toy car, physically attached to a controller hand grip, waited over 50 years for a repair and held memories of a tender relationship between a sister and her brother.

Materials

Tin steel
Epoxy

Processes

Machining
Glueing

the repaired toy car in action

Before we begin our story, we wanted you to see how the toy works.

a tender relationship

Even though our client was seven years younger, she and her brother were incredibly close. Despite living so far away, he was her best friend and a wonderful uncle to her daughter. Sadly, he died suddenly, and the car became a vital symbol of their relationship. Though she remembered the car, she didn’t remember seeing it work.

Since the passing of our client’s brother and after bringing the toy car back to Toronto, it was hard to find someone in Canada to restore the mechanical toy car. Though there were people in the U.S., she was determined to find someone in this country. Four years later, she found our repair shop.

broken control cable and hand grip

A rotating sprung-steel coil cable, similar to an old-style lawn mower throttle-control cable, powered this toy car. A music wire steered the car through the coil.

The control cable was bent and broken, and the hand grip, which housed gear drives, was also broken.

machining and rebuilding a GEAR

The gear was so badly worn that it disengaged from the other gears and had to be replaced. I had to fabricate a new one. You can’t buy a part for something this old.

I rebuilt the drive gear, steering and spring drive cable and the car worked perfectly. The piano wire steering cable received a steel wire coil that doubled as the driving cable.

coil spring

The crank on the handle rotated one rear driving wheel. No, there was no transmission axle to drive two wheels. That would have been too complicated for a 65-year-old tin plate car!

I ordered a coil spring from the U.K., but an unexpected postal strike delayed the repair.

When the coil eventually arrived, it turned out to be too thin. Since I had no choice but to find a way, I attempted to repair the original. Luckily, it did the trick.

Finally, the car was repaired and I sent my client her newly-functioning toy car. You can see it working at the beginning of this story.

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An Unexpected CBC Radio Interview

Donald Dawson — Mon, 02 Dec 2024 18:16:40 +0000

CBC Radio’s Margaret Gallagher, the host and producer of North by Northwest, BC’s highest-rated weekend show, reached out for an interview in early November 2024. Margaret meets creative people from all around the province speaking about their passions and inspirations.

Listen to the 11-minute segment by clicking here.

Invitation to an interview

"We're doing a series on folks working with metals, and I would love to come and visit your studio next week to do a taped audio piece," she wrote.

A half-hour turned into a whole hour of conversation about metal, metal fabrication, restoration, repair, and art.

These were some of Margaret's questions:

How did you get into working with metal?

I was always curious about how things worked. In our basement, I made steam engines out of tomato soup cans.

As a young person, I had a learning challenge and saw a child psychologist. When the psychologist discovered that I took apart clocks, he saw this as a problem. My parents and I did not. What he saw as a problem was my curiosity in action.

What keeps you working with metal?

One of the things I love about working with metal is the joy and surprise of forming metal into various and sometimes unexpected shapes.

And I love teaching and passing on my passion to people of all ages, from 5 to 95.

Listen to the 11-minute segment by clicking here.

machines and tools

We talked about the machines and tools that you can see in the shop, including:

A 1939 lathe from the Jericho seaplane base, which assisted in the repair of seaplanes protecting our coast
Oxygen and acetylene tanks and torches
A propane forge for heating big metal objects slowly and an induction forge that heats metal white hot in less than a minute
A 150-year-old Peter Wright anvil from the Nelson area possibly used in a mine.

restoring and repairing: getting rid of our throwaway society

We discussed how items that people bring to the shop for repair and restoration are rich in history and have sentimental meaning.

These childhood memories are significant and are a reminder of a treasured grandmother, grandfather, aunt, uncle and other family members. Clients who come with these items want to pass them down to the younger generation.

These family treasures are not only physical "things." They are full of memories, histories, and emotions - as if they have a life and a heart.

We don't have to throw everything away. If things are not repairable, we can recycle them.

whimsical art to engage visitors At the Eastside culture Crawl

Many items entertain and engage visitors of all ages during the Eastside Culture Crawl.

We show visitors objects in motion, like the two marionettes: a miniature blacksmith holding a golf club and a hockey stick on his back and whose hat flies off when he gets frustrated. A miniature metal anvil, forge tank and cat accompany him.

Then there's another marionette, Bucephalus, a steel horse weighing 10 lbs.

There is also a resonant metal violin weighing 7 lbs made without formal design drawings but created as close to a 4 x 4 adult violin.

And one year, we had a bicycle-powered pipe organ.

Culture Crawl Enthusiasts on Bicycle Powered Organ Pipe

creative and unexpected commissions

The stork is a water feature co-designed with a client who has two smaller metal storks in his garden and dreamed of having a large one for his fish pond.

For more information and for tours of the shop,

call Donald Dawson at 604-910-6427.

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Santa’s Workshop Music Box

Donald Dawson — Fri, 01 Nov 2024 19:00:44 +0000

Santa's toy workshop music box survived a flood and held immense sentimental value for a client whose parents were the original owners.

Materials

Plastic

Processes

Cleaning
Lubricating

music and movement

It is always wonderful to see the finished product. We feature it before the story because it is so delightful to see it in action. The music and movement came together beautifully.

CLICK ON THE VIDEO, UNMUTE THE SOUND AND ENJOY!

A complete overhaul

This music box played music and also controlled the movements of the various elves and toys. It needed a complete overhaul to restore the music and movement.

several steps

There were several parts to this restoration. The gears needed to mesh correctly, the music box needed cleaning and light lubrication, and the spring needed loosening.

As always, cleaning was the first step, using a three-in-one brand of white lithium grease that immediately loosened up the workings.

The metal comb in music boxes

The music comes from the roll and pins, and the comb brushes against these pins and creates the sound.

The spring and governor, another work for speed regulator, are located in the black plastic box next to the music roll.

Luckily, the metal comb in this unit was in pristine shape. If the metal combs bend because of wear and tear, they need straightening, and that's a tedious process that takes a lot of patience.

a tight spring

Traditional music boxes, like this one, have a spring that you wind up with a key. As the spring unwinds, it turns the cylinder.

In this case, the flat spring was so tightly wound that it had nowhere to go. Fortunately, it was neither broken nor fatigued.

By using the governor (speed regulator) and some dry compressed air to unwind the toy several times, it came loose.

AND FINALLY, SUCCESS!!!

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Sergio Bustamante Moose Sculpture Repair

Donald Dawson — Thu, 19 Sep 2024 20:52:41 +0000

This giant brass moose sculpture, an original Sergio Bustamante, came in broken after a move. It took some consideration to figure out how to repair it.

Materials

Brass

Processes

Cleaning
Soft soldering

Moves often damage precious items

Many clients have had to foot the bill themselves after a move. When you see sentimental pieces and beautiful works of art like this one, it is understandable that they would want it repaired.

We see many items that get damaged during a move. Movers often are unwilling to pay the repair costs when an item is not an easy fix.

In this case, the sculpture was light but awkward, so who knows how many movers could have dealt with an item like this?

soft soldering solution

This moose was roughly 24" x 30" x 40" and needed soft solder repairs.

It was cleaned and prepared for a soft solder to repair the antler and a section near the jawline.

restored patina & A strong repair

The concern in repairing valuable items is ensuring that the repair is strong and that the patina is restored or maintained as much as possible. And that often means complimenting the patina of the original artist.

The soldering repair worked well, and the moose was ready to be hung proudly on a wall in a new space.

about the sculptor

Here's some information about the artist from his website.

"Sergio Bustamante is a prominent Mexican sculptor known for his ability to create expressive and unique works of art. His sculptures fuse elements of nature and Mexican culture, using various materials such as paper mache, bronze and ceramics. His works convey a feeling of vitality and movement. Bustamante has gained international recognition and is considered an influential figure in contemporary Mexican art."

stages of repair

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Mechanical Toy Repairs

Donald Dawson — Wed, 28 Aug 2024 17:53:06 +0000

We love being a toy hospital. How thrilling it was to repair and restore this family of moveable and vocal mechanical dolls for a fantastic, enthusiastic client.

Materials

Music boxes
Wires and solder

Processes

Replacement of music boxes

toys that move and make sounds

These dolls were so cute that you can understand their sentimental value. The client wanted the toys spruced up, and if they could move again, that would be a bonus. Happily, they all went home in full motion and sound. Check out the videos below.

Some of these toys, with wind-up music boxes, had broken or worn-out springs.

These mechanical dolls needed new music boxes installed. The music boxes were not the same, and neither was the stuffing in the dolls. These new music boxes had to be well-wrapped in cardboard or plastic because the dolls’ stuffing would have interfered with the mechanical workings.

Jack-in-the-box snowman

Click to play

This jack-in-the-box snowman needed the electrical wiring secured to prevent breakage.

The corroded batteries and their holder required replacing.

The mechanism in the box needed some filing to fix its badly damaged gear teeth.

cackling witch

The witch and her umbrella dress required a repair of its metal spine, glue for the failed plastic parts, and soldering of her electronic parts. This toy witch was a perfect witchy character in sound and looks. You can hear her cackle in the short videos below.

Click to play

musical clowns

These two clowns needed their music boxes repaired.

Now, with a turn of their red noses, they were ready to delight their owners and new audiences.

music boxes and Buying locally

Some wind-up music boxes are not repairable, but there was a local supplier to help with this project.

Buying locally is terrific because it supports fellow Vancouver entrepreneurs, and because buying online is not the same thing as being able to go to a local store.

In a local store, you can see and touch the product and talk to people who know it well.

When it's not on a screen, you know what you are buying. Of course, sometimes you have no choice but to order off the Internet, hoping that the parts come on time. Since COVID, that's been a universal issue.

There's nothing like real live contact.

A big thank you to magic box hobbies!

Magic Box Hobbies in Vancouver is a perfect example of a local supplier who is generous and supportive - and who sends us the best clients.

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Saving Rusted Objects

Donald Dawson — Tue, 20 Aug 2024 18:19:57 +0000

Do you sometimes look at a rusted item and think it’s too far gone and you’ll need to throw it out? Luckily, that’s not always true.

rust still has life within it

Rust is sometimes, but not always, the end of an object.

There are more rusted metal objects to modify, restore and repair than you can imagine.

When an item is still salvageable, newly fabricated parts for those rusted areas work well.

Can you imagine the cost of replacing these items? The waste of money?

And the trash it would have created?

No. That’s not how we care for our valuables, and it’s an unnecessary expense for you and the ecosystem.

We need our history and heritage preserved.

centrepiece and legs reproduced

Can you imagine that this centrepiece could be replicated?

Just below it, look closely at the table legs on the left. They were replaced by new legs, following the same pattern as the original.

This is a patio table that my client wanted restored so his elderly father could use it in the summer. It was a perfect size and had a beautiful faux marble top. It would have been a shame to throw it out. I fabricated a new centrepiece and new legs.

Isn't it great to see that this heritage piece went home for many more years of use?

1943 Canadian Army Footlocker

A grandfather's rusty WW2 footlocker came in for rust removal and new, regulation army-green paint. The intention was to pass it down to a new generation and those to come. It stored bolts at the family hardware store and will now store keepsakes and toys.

New hinge parts

New hinge parts saved this Japanese stackable cabinet.

vintage signs

Vintage collectors like signs, oil cans, licenses, toys, farm equipment, and more. Many of these items are metal, and metal can rust.

In this case, our client needed a stand to support the Shell Gasoline curbside sign, but as you can see below, the rust was pervasive.

Cutting away some of the rust and fabricating the necessary parts to replace the damaged areas worked perfectly.

andiron

Here’s an andiron for an old, deep fireplace. The family loved it and wanted to see if it was restorable.

The andiron was rusty, and its two feet had broken off. However, neither of those factors prevented me from cutting the legs slightly and welding the piece back to a serviceable and workable quality.

look around

Don’t give up on your pieces.

Rust is not the end of life for metal objects.

Let’s get rid of our throwaway mentality.

What do you have in YOUR home that you would want to see salvaged?

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Family Heirlooms Are Full of Emotions and Stories

Donald Dawson — Fri, 02 Aug 2024 18:17:47 +0000

Family heirlooms and other treasures are more than mere objects. They’re not old dead things. They capture memories, stories and the emotions of a lifetime. That’s what makes them precious. And fixing things fits right in with my motto: "Let's get rid of our throwaway society."

I have had many clients bring in any number of childhood treasures reminiscent of a time they wanted to keep alive.

In many cases, they wanted to pass them on to the next generation of family members because they knew the tenderness of memories.

A father and son project

As a teenager in the early 1980s, I made this stained-glass window with my father. It was a perfectly imperfect father-and-son project.

You see, my father and I purposely chose to make the slight imperfections. Dad and I didn’t need to make it pristine. We were learning together, creating a beautiful piece and enjoying the process.

Later, different family members enjoyed this heirloom as it travelled from Vancouver to Telkwa, B.C. and, unexpectedly, to my delight, back to me.

When it came back, I considered giving it a gentle restoration to care for the wood frame. I wouldn’t touch the glasswork because nothing had changed, not even the original intentional sag in the lead work.

Precious statues

People have sent me their treasures from Vancouver Island, the Kootenays and the Okanagan. They ship them over for repair and restoration, and they get them back intact with careful packing.

A statue of the Goddess Diana came to me in many broken pieces. This heirloom had been in my client's family for a long time, passed down from grandmother to mother. Now, the mother wanted to pass it on to her daughter.

This beauty was not meant for the garbage.

I have restored many statues over the years.

saving a perfect-sized patio table

Clients bring in many things that have been in their family for a long time.

This patio table was a perfect fit for my client’s elderly father, who enjoyed sitting outside in the summer. I fabricated new legs so that the father could still enjoy it. It was still a beautiful piece with a lovely faux marble top. Not something to throw away.

MOVERS BREAK things, unfortunately

Many precious items break during moves.

The owners of this marble-topped table brought it to me in 16 pieces. I wasn't sure if I could put it back together but they were willing to have me try. It was valuable to them, and a real beauty.

People have sent me their treasures from Vancouver Island, the Kootenays and the Okanagan. They ship them over for repair and restoration, and they get them back intact with careful packing.

Do you have an object or heirloom that you treasure?

Do you need advice on repairing or restoring something?

Send me a picture, and let's discuss it. Then, I can give you a sense of what I can do.

other precious and repaired items

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