It's a long shot, but....

[Seadog]

In the process of trying to help a neighbour and save them some money,the inevitable happened.
He has two roof lights of unknown manufacture but about 30 years old. Cracked pane in one which we need to measure to get a replacement. In trying to remove the assembly the damned hinges, made of mazak of all things, decided to give up the ghost.
I've an idea of how I'll repair them but the preferred solution would be to find replacements. Pretty unlikely I'm sure, but maybe someone here can help. Two would be great, four even better.

 

[rikrobson]

the HLS 2000 system is meant to repair mazak. I Got some but the mazak i was trying to repair had a too lower melting point.

 

[grim_d]

I know this doesn't help you at all, so apologies about that but I had to google Mazak as I had never heard of it.

In the background on the TV I had Youtube on with a mrpete video showing an old atlas lathe, just as I typed Mazak into google he stated that the backgears were made of of Zamak. Which is pretty much the same thing as I now understand, pot metal?

Coincidence is a funny thing sometimes.

 

[rikrobson]

Mazak is the UK name for Zamak, which is a pot metal Zinc Aluminum Magnesium And Kunifer
It was licenced in the UK to a guy whos initials was MA and used a different zinc (it was less pure due to different refining techniques) So it was called Mazak to differentiate. Now I think mazak just means pot metal but the original was to a specification whereas potmetal could be whatever was in the pot.

 

[Kent]

Put a new rooflight in imo. Even a recent reclaimed one will be a better bet

 

[The_Yellow_Ardvark]

@Seadog
Thinks of it this way.
A great reason to make a forge to melt alloy to allow you to cast a new set.

I have had used JB weld on something similar on a smoke vent. I wrapped it is copper wire then used JB weld.

It held for over 12 months until the building was knocked down.

 

[rikrobson]

Back to the Lights. Are they a standard size? I suspect finding a replacement the correct size may be an issue and new ones will need to be installed.

 

[rikrobson]

have you access to a milling machine? I suspect Ali one could be made fairly easily.

 

[Seadog]

To answer most of the above, not necessarily in any order -

An odd size so would involve quite a bit of hacking around, which I might add, I won't be undertaking

Milling machine - No, not enough space at present, but I have milled with the pillar drill before, and have just had a go at making a replacement piece. Still a fair bit of filing involved too.

Using Araldite to affix aforementioned piece, then probably a couple of small brass rivets through the whole lot to add some strength.

Aware of Zamak, but only relatively recently, when I too started watching Mr Pete.

Not sure I'd like to weld/solder/braze Mazak, or whatever they call the repair technique, with HLS2000, but I will check it out from interest.

Thanks for all of the replies.

 

[the black box]

Wouldn't it be a case of a piece of 12mm think ali cut to shape and a couple lugs tigged on? Or does it require a hollow on the underside?

 

[Seadog]

Yes it would be, in an ideal world. Since I don't have a tig or anyone nearby who I know of with one, I'll have to make do with my current solution. A tig is on the want list, but first of all I need a lot more room.

 

[Pete.]

@Seadog
Thinks of it this way.
A great reason to make a forge to melt alloy to allow you to cast a new set.

I have had used JB weld on something similar on a smoke vent. I wrapped it is copper wire then used JB weld.

It held for over 12 months until the building was knocked down.

I always wondered who was responsible for this

 

[Seadog]

I'll also add that a furnace is also on the list of wants. I've not done any casting since school, 50 years ago.

 

[The_Yellow_Ardvark]

@Pete.

Not me. this time.
I am The Innocent Vark.

 

[cocker]

I always wondered who was responsible for this

View attachment 90709

That is awesome

 

[Bill Edwards]

I always wondered who was responsible for this

View attachment 90709

Wow, just wow!

 

[Bill Edwards]

Could the lights just be replaced with modern LED floodlights? They're so cheap and of course use practically no electricity.
Here's two (small, 20w) ones, at £12 for the pair delivered:

http://www.ebay.co.uk/itm/2x-20W-Co...874946?hash=item5424d02a42:g:KnwAAOSw0fhXjaFW

 

[Seadog]

I think you've got the wrong end of the stick Bill, they're roof lights. Bits of glass to let the light in.

 

[rikrobson]

Do they need to open?

 

[Seadog]

We looked at fixing them, but they're metal framed and not easy to do. Also no easy roof access as third floor and the roof has has been closed in too.