Toy Repair Archives - Donald's Innovations & Repairs

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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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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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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Toy Tractor Model Restoration

Donald Dawson — Wed, 12 Jun 2024 17:31:01 +0000

This 4.5’ x 4.5’ x 8.5’ steel toy model of the Cockshutt Model 30 Row Crop Tractor came in for a complete restoration and detailing from a client who lives on Vancouver Island. He intends to donate it to a collectors’ museum in Ontario.

Materials

Steel and rubber
Masking tape
Paints
Vinyl decals

Processes

Fabrication
Straightening
Sandblasting
Masking
Painting
Decal application

Background

The original tractor manufacturer, Cockshutt Farm Equipment, was founded in 1877 by James G. Cockshutt in Brantford, Ontario. Initially, the firm distributed American-made tractors and designed accompanying implements. Eventually, the company ended its U.S. agreement and decided to design and manufacture its own line of tractors. They manufactured this style of tractor between 1948 and 1958.

DAMAGES

As you can see from the images, this toy tractor came in with much of the paint worn off and without a steering wheel. To begin, I straightened the toy tractor wheels and steering yoke. I then stripped the paint with the sandblaster. However, I needed to protect the rubber on the wheels before sandblasting and used masking tape for that process.

fabricating a steering wheel

Since there was no steering wheel, I had to fabricate one. I coiled some 3/ 32" diameter steel bar, cut and bent to form a circle by eye and machined, and cut the spokes for the steering column. I created a steering wheel by bending the hand wheel and machined the spokes to attach to the column.

painting challenges

I matched the original paint to be as close as possible to the original and used spray paints, giving it yellow for the wheel hubs and red for the tractor body. The yellow paint took three coats because the pigment kept separating.

The red, on the other hand, was smooth as silk.

painting Prep

VINYL decals

For some beautiful die-cut vinyl sticky-back decals, I contacted Business Now Services, Inc. I emailed my rough sketch, and they created precise artwork using the colours and measurements I provided. The original decals were barely visible on the toy tractor when it first came to me.

Finally, I painted and assembled the tractor and applied the vinyl decals.

An articulated toy farmer will hopefully fit on the tractor seat.

A huge thank you to @businessnowvancouver for the die-cut vinyl sticky-back decals.

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Museum Gas-Powered Model Seaplane Restoration

Donald Dawson — Tue, 04 Jun 2024 20:01:29 +0000

This gas-powered model seaplane, with a six-foot wingspan, is displayed at the MONOVA Museum and Archives of North Vancouver in their BC coast transportation gallery. I restored it for the opening of their new museum in 2020.

Materials

Basswood
Model airplane tissue paper
Wire rope
Wood gussets
Glues and paints

Processes

Stripping
Cleaning
Fabricating
Re-skinning
Painting
Decal application

An Airframe Overhaul

This model seaplane was to be positioned up high from the ceiling in the museum. It was in poor shape and required an airframe overhaul. I stripped the tissue off the wings and fuselage and sanded the airframe. Throughout the plane, I found dead spiders and cobwebs. When I peeled off the layers of painted tissue, I discovered the original owner's name and address inside the cockpit. The old telephone number designation started with N-O. That's how old this thing was.

The original frame, in balsa, crumbled to the touch, so I repaired the frames, installed new section frames of basswood, strengthened the loose framework with wood gussets and glue, and cleaned the cockpit window.

Once the frame was sturdy and reinforced and the cobwebs were gone, the seaplane was ready for a new skin and paint.

new skin and paint

There are many reasons for a restoration. Natural elements and human contact can damage aircraft models like these. Some things made in the past are not necessarily safe to replicate. Solvents and paint are a significant concern to our health and expensive, too! You may remember the toxic effect of lead or toluene. Luckily, modern acrylics can mimic the same patina, shine or surface texture.

The tissue application for the body was next. I had to wait for the glue to set on the frames to apply a spritzing of alcohol and water to shrink the skin and remove wrinkles.

Many coats of paint began to stiffen the tissue and freshen the model. It was a cycle of painting, drying and smoothing wrinkles. I used a spray base and brush strokes to create the original look.

Wing and tissue drying

Torn fuselage underbelly

Protecting pontoons & Applying call-letters

The seaplane got temporary plastic bags as gum boots to protect the pontoons from wear on table surfaces, until it would be hung in the museum.

I carefully applied new decals after mapping out the call letters and arrow placements. The new white call letters were then ready to be painted onto the red wing skin, and I placed the arrows on top and underneath the port and starboard wings. The plane's body got a red arrow on both sides, and the wings got the new Canadian call letters.

replacing cable sTays

The cable stays for the tail wings were replaced and required tensioning.

Finally, I applied an archival ultraviolet-resistant clear coat to harden the surface.

The seaplane was now museum-ready.

THE DAMAGE

REPAIRS IN STAGES

Painting body

Applying tissue to body

Basswood wing repair

Applying tissue to wings

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1948 Indian Chief Model Motorcycle

Donald Dawson — Fri, 31 May 2024 17:32:56 +0000

This exquisite Danbury Mint 1:10 scale model motorcycle was shipped and received in pieces.

Do you think this kind of breakage is a one-off incident? Not at all.

Materials

Plastic
Leather

Processes

Clamping
Glueing

BROKEN BEFORE SHIPPING? MAYBE.

I regularly repair items that get shipped in such poor or inappropriate packaging that the expensive item breaks or bends, and I shake my head, wondering, “What were the sellers thinking?”

In this case, its sturdy Styrofoam packaging was perfect for the item, but the model came in pieces. My client and I decided it must have been broken before shipping.

BROKEN & loose parts

These are the broken or loose parts that I repaired: a footpad, handlebars with the brake lever, the bar that holds the handlebars together, the throttle control cable, the lights, the rear pannier rack, a saddle bag strap and the metal parts of the windshield.

MANY WORKING Parts ON THIS MODEL

Did you know that there are many working parts on this model motorcycle?

Can you guess what parts they are?

Give up?

these parts work

These parts work - the starter, clutch and brake pedals, side-shift lever, front and rear suspensions, and saddle suspension. The seat’s genuine leather, and there’s a removable windshield and removable, real leather saddlebags. All the small details (bars, handles, cables, wires, rivets, bolts, nuts, etc.) are crisp, well-chromed, and well-proportioned. There are no decals – all details are in 3-D. There are two working kickstands – a full-prop one behind the engine and a lean-over bar with a pad that swings out from the left side. The medium blue-and-black paint job is glossy and flawless. The genuine wire spokes and chrome wheel rims look sharp.

HOWEVER, do not let anyone play with these parts. Not even you. Why?

Although they look and work like the real thing, they are delicate. As delicate as fine china.

Stabilizing the model, and a final aerial shot.

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50-Year-Old Doll Back in One Piece

Donald Dawson — Wed, 08 May 2024 17:42:19 +0000

When people bring us toys to fix, it’s because they are important and meaningful to them. So many good memories come with these toys; this plastic doll was no exception. Like many items that come to me, these treasures have deep sentimental value.

Materials

Braided rope
Metal tools

Processes

Restringing
Cleaning

DAMAGE

This sweet doll came in for a limb and neck re-attachment. She was made of plastic and was from the 1950s era.

Complexities

This job took time. If there’s an easy and obvious exit at the back of the body or head, as is often the case, then the job is easier if the intention is to connect the body parts and if there is no other damage. You’ll see in another post how a 117-year-old doll with much internal damage made of porcelain was so much more challenging to repair.

Initially, I thought the voice box would be a good access port, but it was glued in place, and I couldn’t remove it. The voice box itself worked and did not need repair.

tools for narrow access points

To find elastic braided rope, I had to go to a mountain climbing store. I relied on the stretch of the rope to anchor the limbs against their joints.

It was tricky to tie the knots, so I had to create some tying tools to get between the limbs and body through the joints. I fabricated some tying tools that resembled long tweezers. The knots had to be tied extra tight for the limbs to pop back into their sockets.

I removed the old rope and looped the new rope through any eyelets or links internally through all the limbs and the head. Her eyes were not an issue. They opened and closed perfectly.

I started with one of the eyelets in the head, looped into one leg and arm and across to the other leg and arm. Then, I finished stringing the other eyelet of the head and stretched and tied everything together.

What took a long time? Fiddling with rigid, narrow access points.

final touches

The last stage was cleaning the doll. I combed her hair with a light brush and removed the dust from her clothes.

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ET Toy Repair

Donald Dawson — Sat, 20 Apr 2024 17:20:38 +0000

When this electronic ET toy came in, its owner, a middle-aged professional, had just helped his parents empty their home. He could have kept many things, but this one was particularly significant. He knew that restoring it to working condition would keep his childhood and his parents close to him forever. Childhood items hold precious memories for many people - more than you would probably guess.

Materials

LED lights
Resistors
Coloured lights
Switch
Heat-shrink tubing
Glue

Processes

Removal of battery corrosion
Soldering
Gluing

The damage

When my client first got ET, that famous finger and its two eyes lit up from a switch at the back of the toy. My goal was to get it to light up again.

Technology had changed, and the long incandescent lamps ET once had were no longer made. However, LED lights were the perfect option. Together with a mess of resistors, coloured lights, wires, and a switch, I knew that I could restore it to its former glory.

ELectronic challenges

I removed battery corrosion and sheathed the many long wires with heat-shrink tubing. The lamp circuit was a parallel circuit with the switch in series to turn the lights on or off.

I mounted the tiny switch within the old switch casing to look like its original switch.

ET - reADY TO PHONE HOME

Within a few days, I was able to restore his childhood treasure and ET toy could phone home again.

a big shout out

A big thank you to Magic Box Hobbies @hobbiesmagicbox for your ongoing referrals and support.

And to Lee's Electronic Components @lees_electronic for expert assistance finding the best match for the old incandescent lights. I can always count on them to supply electronic parts.

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