| As a technical note, you can go up to the File
tab in Internet Explorer (and possibly others), hit Save As, and
save this page to your computer for future reference. It will save
the thumbnails as well, but the links to the full-size images will
still require that you are online to see them. Recently Bryan asked me to detail and photograph a procedure for
cutting the small notch in the newly available case clamps using a
drawing provided by Rob.
We wanted to use only tools available to most anyone so it was
suggested that a common Dremel type tool be used. Lucky me because I
just happen to have a Dremel set and I bet most people have access
to a similar tool and they can be had cheaply enough if not.
The cutting burr I chose to use is the number 9903 tungsten carbide
cutter. The number 9901 will do as well. The case clamp is
fabricated of stainless steel so I would not suggest a stone or high
speed steel cutter. Also please be aware that these cutters will
throw tiny, very sharp slivers of stainless steel, not good for your
eyes so please take precautions.
The photographs show the fitting of a new case clamp to my late
model, round label Royal Aqua-Master. This is my best and most
favored regulator and I surely wanted a case clamp for it but like
many Aqua-Masters the case clamp will have to be notched at the
exhaust port for clearance and a proper fit. There is no particular
difficulty or magic to cutting this notch, just go slow, a little
bit at a time and you will be successful. Absolute accuracy is not
needed but pay attention to getting the notch cut at a position that
allows the ports to sit at the correct angles relative to one
another and allow the fastening screw to center on the flat area on
the back case approximately.
The tools you will need are a Dremel type tool, tungsten carbide
cutting burr(s), small round file or Emory cloth, small clamp or
vice, Sharpie marking pen and a well lighted area. I used the
kitchen table because my air-conditioner in the shop quit and it is
106 degrees in the shade.
Below is a step by step description and pictures:
1. Remove the case clips using your preferred method. I use a small
end cutter to grasp the clips and then pull them outward and
downward. This method does not damage the cases or the clips (should
you wish to use them in the future).
2. Use the Band Clamp Notch
Template from Rob. Lay the new case clamp out on center over the
drawing.
3. Use your Sharpie marker to outline the area to be trimmed. Draw
the are on to the clamp as closely to the desired cut as possible.
That way when the marker is gone, the cut is completed!
4. Do a test fit to ensure that you have the intended cut located in
a position that will work for your regulator.
5. Secure your clamp into a small vice or some wooden clamps as I
used. Be careful not to damage the new clamp with the vise.
6. Use the Dremel to slowly remove metal from the marked area on the
new clamp. Just remove a little metal at a time, do not force it,
let the burr do the cutting. Paraffin can be used as a lubricant if
desired.
7. You may want to check fit the clamp at this time to see how it is
looking for you. Use the Dremel to adjust the cut as required.
8. Remove the clamp from the vice, use a small file or Emory cloth
to smooth the jagged areas and provide a smooth finish.
9. The finished product. Pay attention to achieve a smooth finish
and rounded corners.
10. Install the clamp onto the regulator. Tighten it up and
determine if the cases are drawn together securely. If with moderate
force you can rotate the cases then you may need to remove the case
clamp and gently squeeze it uniformly at several locations using a
Vice Grip pliers or similar tool. Be careful, just a little bit at a
time until the case clamp draws the assembled unit together
securely. Note: When reassembling the regulator be sure that the
diaphragm tabs (DA and RAM) are centered over each of the second
stage lever arms for proper operation.
11. Royal Aqua-Master, the name says it all!
Good luck with your new case clamp, your Aqua-Master will thank you
because now you can keep it clean without the old clip hassle. Happy
diving.
Nemrod
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