Filbert Pump Base Repair Instructions.


Filbert Pump Base Repair Instructions.

This repair is easy, but please read the instructions before attempting the repair. I know this advice is contrary to all good judgement, commopn sense, and human instinct. However, if you don't want to make a mess of something, read the instructions first. The instructions are purposly made short for those of us, myself included, who know everything, and wouldn't admit it even if we didn't, but we do. Alright, at least read the next line...

Caution: The tube is lubricated with silicone grease. To keep the tube clean, leave the bag on the tube until you are ready to insert the piston.

Replacing the pump tube and base:

1. Remove the three screws under the handle and remove the top half of the pump from the large tube. Put the screws in a safe place because you will re-install them shortly.

2. With a tissue, wipe off the loose dirt and grime from the piston assembly. The piston assembly does not have to be spotless but do remove the big chunks of caked dust. If you remove the rubber seal be sure to replace it in the same orientation, which is with the open side toward the bottom of the pump.DO NOT WASH THE SEAL WITH SOAP AND WATER, it will remove the silicone lubricant and adversely affect the operation of your pump. Simply use a tissue or paper towel to wipe off the excess crud.

3. Insert the piston in the new tube:

 

Look at the picture and note the location of the large hole.

When you put the piston in the new tube insert the piston at an angle and push it in as far as it will go while keeping it at an angle. The orientation of the piston relative to the large hole is important, and will prevent the piston lip from turning over when the piston is straightened.

When the piston cannot be pushed in any farther tip the piston while pulling it out ever so slightly. When the tube is straight pull it out just a little bit more, but not past the large hole, to make sure the piston lip is not turned over.

Next push the piston in the tube about 6 inches and pull it out about 4 inches. This will further serve to straighten the piston lip in the event is turned over.

Now, you can push the piston in all the way, align the four holes in the large tube and re-install the screws. Do not make the screws too tight otherwise, the threads will pull out of the plastic.

Your pump should now be ready to inflate those balloons.

If you have, any questions give us a call at 518-765-4585.


If the screw holes do not line up, fear not, the repair is now more complicated, but still simple. The reason the screw holes do not line up is that some of the first pumps of the new design, yours is one of them, had the screw holes drilled by eye. This is because the jig to drill all holes the same was not completed at the time your pump was built. In fact, you do not need any screws at all to use the pump with the new base, the handle will not come off in use. It might come off when you carry it, although that is not very likely, but it will not come off in use, so if you are short of time you can put the new base on your pump and do your gigs with confidence. If you do not get this repair completed before your next gig put the pump together with the new base, line up the big holes, and do your gigs, then finish the repair in your leisure time.

Here is how to solve the problem.

Gather your tools. You will need a drill, a 5/32 drill bit and an 11/64 drill bit, and you will need a Phillips screw driver, a #2 Phillips fits the screws best.
First put the new base on the pump and push the piston part way in and stop. Now take three or four paper towels and stuff them into the pump around the push rod. This will keep plastic chips out of the pump when you drill the new holes.
Now put the handle on the large tube and line up the large holes in the tube and the handle. Next find the screw hole that is the closest to being in line and line those holes up. Now look to see how much of the large hole is covered. As long as at least half of the large hole is open the pump will function properly with no noticeable difference because it was designed with the breather hole larger than necessary just in case it became covered or partially plugged. In fact, the pump will operate with the breather hole completely plugged, and the only noticeable effect will be that it will be slightly more difficult to lift the piston.

The next thing to do is to put a screw in to anchor the tube and handle together so they won't move.
At each of the other two screw holes in the handle, and using each of those holes to guide the drill, drill a hole in the tube with the 5/32 drill. Now there should be three hole in the tube that line up with each of the screw holes in the handle. With a pencil put an X mark on the tube under each of the holes you just drilled and an "O" mark under the hole with the screw in place. Three holes, three marks.

Next, remove the screw from the handle and remove the handle, but do not pull the piston out just yet.
Next, drill each of the holes with an "X" below them using the 11/64 drill. This will make these holes slightly larger.
Now take a screw and screw it in each of the holes with an "X" beneath it. You will have to push as you turn the screw to get it started. Push as you turn the screw until the screw comes through to the inside of the tube. Then remove the screws from the tube and, while laying the pump on its side, remove the piston. The paper towels should pull all of the plastic chips from the tube as the piston is removed. Inspect the inside of the tube and remove any chips that slipped past the towels and the piston.
Notice if there are any burrs on the inside of the tube at the holes you drilled. Remove these burrs with a knife held flat against the tube inside wall, and remove any remaining chips from the inside of the tube.

Now, put the piston in the tube about half way and move it up and down a few times to be sure the piston lip is not turned over on itself, then put the piston all the way in. Now line up the screw holes in the handle with the three marks on the tube, making sure the large holes line up as they did when you drilled the holes. You should now have the three screw holes in the handle lined up with three screw holes in the tube. Put in the three screws, snug but not tight, because you are working with plastic and too tight strips the threads from plastic, and you are finished.

Wasn't that easy? If you have any problems give us a call, 518-765-4585.

Last Update 6-6-2010