Spine repair

First introductory remark:

The content of this and the sides following under "Detail representations" is published under the reservation, that these only are certain to the private use, also to the help for a good friend. Every further use of the here offered information, especially for commercial purposes, for offers in the total or in parts or for services are forbidden.

Second introductory remark:

The in this chapter used materials were delivered by different offerers. The measurements are nominal values. They take no tolerances caused by the manufacturing process into account. In the most favorable case, the individual parts match, otherwise they must be retreated.

Raw materials:

1.	Round tube	Aluminium	AlMgSi 0,5 F22 WK 6060	30×4 according to drawing
2.	Round tube	Stainless steel	V2A (X5CrNi18 10) WK 1.4301	22×1,5 according to drawing
3.	Rod	Polyamide 6.6, glass fibre reinforced	PA 6.6 GF 30%	Ø 20 according to drawing
4.	Lens head screw	Steel	4 pieces	M4×40
5.	Hexgon nut	Steel	4 pieces	M4
6.	Tooth lock washer	Steel	10 pieces	Inner Ø 4,3
7.	Two components adhesive	Metal to metal connect
8.	Cyanacrylate adhesive	Metal to polyamide connect
9.1	Self tapping screw	Steel	2 pieces	M4×30, variation
9.2	Two components adhesive	Polyamide to PVC connect		variation

Tools required:

1.	Jigsaw or circular hand saw	1 sawing blade for non-ferrous metals 1 sawing blade for stainless steel
2.	Drilling machine with stand	1 driller Ø 4 cobalt coated 1 reamer 12 mm
3.	Lathe
4.	Grinder	Mounted points Ø 20 and 25 Grinding brush Ø 20 Cylindrical cutter Ø 12

The tolerances of the stainless steel tube didn't require any further treatment. It was given up because of the difficult machinability. But, stainless steel tubes of the chosen size are produced in welded implementation with longitudinal seam. It is possible the weld must be ground.

Work steps (Variation with adhesive):

The three parts saw in the length according to the drawing and deburr.
Turn the 19 mm shaft of the polyamide rod according to the drawing with help of a flat file. Realize the tolerance compensation on this occasion to the inner diameter of the back tube of the doll skeleton.
Equip the motor part of the lathe with a chuck. Then enlarge the inner diameter of the range B--B to the outside diameter of the back tube of the doll skeleton in accordance with the drawing. Realize the tolerance compensation on this occasion to the outside diameter of the stainless steel tube.
After successful trial assembling glue the stainless steel tube with the polyamide rod with cyanacrylat adhesive.
Glue the stainless steel and the aluminum tube with 2 components adhesive. Let's cure.
Drill the holes in accordance with the drawing drill and cut lightly. Possibly you must deburr in the inside of the stainless steel tube.
Shorten the back tube of the doll skeleton including the fragment by 100 mm (it corresponds to the length of the stainless steel tube).
Demount the hip pin with help of two mouth-keys wide 11 (Nominal value).
Insert the hip pin into the stainless steel tube. For fixing install two M4×40 screws, install the nuts and the tooth lock washers and tighten.
Roughen the rod as well as the inner side of the PVC tube. After it spread with 2 components adhesive and insert speedy into the back tube. Attention: You have only one trial.
To fix the implant use one of the M4×40 screws, install a nut and the tooth lock washers and tighten. Alternatively the screw can spread with two component adhesive and put in after it.
Insert the hip pin into the stainless steel tube. To fixing two M4×40 screws, install the nuts and the tooth lock washers and tighten.
Remount the hip pin into the hip joint.
After about one day test the tight fit of the screws and when indicated tighten again. Then, the Doll can be closed.

Work steps (Variation with self tapping screws):

The three parts saw in the length according to the drawing and deburr.
Turn the 19 mm shaft of the polyamide rod according to the drawing with help of a flat file. Realize the tolerance compensation on this occasion to the inner diameter of the back tube of the doll skeleton.
Equip the motor part of the lathe with a chuck. Then enlarge the inner diameter of the range B--B to the outside diameter of the back tube of the doll skeleton in accordance with the drawing. Realize the tolerance compensation on this occasion to the outside diameter of the stainless steel tube.
After successful trial assembling glue the stainless steel tube with the polyamide rod with cyanacrylat adhesive.
Glue the stainless steel and the aluminum tube with 2 components adhesive. Let's cure.
Drill the holes in accordance with the drawing drill and cut lightly. Possibly you must deburr in the inside of the stainless steel tube.
Shorten the back tube of the doll skeleton including the fragment by 100 mm (it corresponds to the length of the stainless steel tube).
Demount the hip pin with help of two mouth-keys wide 11 (Nominal value).
Insert the Hip pin into the stainless steel tube. For fixing install two M4×40 screws, install the nuts and the tooth lock washers and tighten.
Insert into the back tube. To fixing use one of the M4×40 screws, install a nut and the tooth lock washers and tighten.
Expose the cross tube approximately 5 cm (or 2 inches), drill 2 holes Ø 3,5, and turn in the self tapping screws and tighten. Fill again afterwards.
Remount the hip pin into the hip joint.
After about one day test the tight fit of the screws and when indicated tighten again. Then, the doll can be closed.

Problems:

It is to be assumed that the shortened cross tube approximately 20 mm (a bit more than ¾ inches) must be completely exposed. In this case existing materials of the foam block are to be removed from the tube with sand paper.
A nut cannot be appointed within the foam block. Therefore the screw can be fixed with the two component adhesive.

Detail representations:

Initial situation

Individual parts

Used tools and materials

Assembling the implant

To display the drawings the Adobe Reader needed.

Please pay attention: 1 " = 25.4 mm and 1 kg = 2.2046 lb