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Using tin snips the structural back is cut and the roller disassembled. The plastic end caps are pulled from the roller which removes the spring and locking mechanism. Next the shutter is unwound and lid sideways out of the roller. The roller tube is cut 0.1 inches shorter than the desired width. The end caps are installed and the shutter material is cut to width to fit in between the caps. Then the shutter is cut to the desired length plus one inch. The top cut end is folded and sewn as was the original.
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In this case the steel axle had to be cut and a flat reformed to stay with in the desired width. The round was convert to a flat with a hammer and anvil. Final finishing was provided by hand filing. The opposite cap was modified by removing the locking ratchet with a sharp knife.
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The left support bracket has a slot filed in it to receive the flat ended roller axle. The right bracket was drilled and threaded to accept a #10-32 Thd screw which would be the stub axle for the other end of the roller. To make a bearing surface the exposed screw threads were filed off, and a brass tube insert that would slide over the modified screw was glued in place with JB Weld. The support end brackets were made from 0.050 inch thick stainless steel.
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Checking for fit after mounting the attachment brackets using the rear two rivets on each side. Note: the sewn end of the shutter and the ends have been cut at a 45 degree to clear the end plates where they intrude into the tube.
To prepare for final assembly the dam was put into place and riveted. Next the pull string guide tube was fitted and permanently fixed into place. Using a small diameter wire, the woven fish line pull string was fished from the outer end up to the radiator. After the dam had been installed, the assembled shutter roller is slid into place. Then the flat ended axle is inserted into the slotted bracket and the roller rotated several times to pre-tension the spring. While preventing the roller from turning, it was pushed to the left, slid into position and the screw threaded into place. Then the bottom of the shutter was pulled down and out so the fish line could be tied to the cross bar in the bottom of the shutter. |