1. Renewing existing parts
One of the difficulties with Meccano is that parts with bosses can be a problem as they can be distorted or broken. Examine the parts before you use them as you may need to take remedial action. This may often be little more than a sharp rap with a hammer and suitable punch in order to tighten up the reamed connection.
Another point to remember is that you do not improve the holding power of a boss by inserting two screws in opposing holes. This can lead to a wobble as the boss is not held parallel to the rod and two bolts are twice as likely to work loose as one.
2. Making new parts from existing parts
When buying old Meccano, it is very often the case that you find you have large quantities of the common parts which were supplied in small sets: for example 2½” perforated strips, 5½” perforated strips, 3½“ x 2½“ flanged plates, 1” pulleys, etc. These common parts can be cut up using tin snips or a metal saw plus a file into less common or more valuable items: for example a 5½“ perforated strip can become a 3½“ strip and a 2” strip, the flanged plate cut into two 2½” x ½“ x 1½” girder brackets, similar to part 161 but more useful, and the pulley boss can become an oversize collar. Perforated strips can also be bent using a vice and hammer to create double angle strips. To obtain the correct placing for the bend, bolt an existing double angle strip to the perforated strip so that you can place it in the vice jaws at the correct height. In this option, a 12½” perforated strip can become a 5½” double angle strip plus a 4½” double angle strip, both rare items.
3. Sourcing alternative parts
Throughout the history of Meccano, modellers have sought to extend the system to enable them to build bigger and more complex models. This was encouraged to some extent by Frank Hornby who advocated the use of cardboard before the system offered flexible plates. Extending the system can be quite a contentious subject depending on the degree of “purity” to the Meccano system that your audience feel you should achieve. If you are not too worried, or your need is just too great, substitute and system extension parts may be sourced as follows:
a. M4 bolts and half nuts can be purchased by the thousand at very reasonable prices from suppliers such as Westfield Fasteners. The M4 thread differs from the standard Meccano Whitworth thread and the nuts and bolts are not interchangeable. It follows that M4 bolts cannot be used in brass bosses. If you decide to use M4 parts, make sure you purchase stainless steel nuts and BZP bolts as this combination works well.
b. M4 screwed rods are sold in metre lengths in B&Q
c. M4 washers will serve for both M4 and Meccano bolts and are generally of high quality
d. Many interesting electrical parts can be purchased from Maplins and easily adapted for Meccano use. Their microswitch with lever can be used as effective limit switches as well as for automated sequence control when driven by cams. They also offer toggle switches, connectors, etc.
e. Many Meccano suppliers list electric motors which are powerful and have in-built reduction gearing which frequently solves problems which standard Meccano motors cannot.
f. Grub screws: – Screwshop at http://www.screw-shop.com/532-bsw-x-532-steel-slot-grub-screw-radius-point-ct-pack-300 sell 5/32” x 5/32W grub screws at 300 for £16.20 (inc. VAT). That’s equivalent to a unit cost of 5.4 p. A couple of years ago I placed an order on-line for 600 and the screws arrived within two days (post free). Whilst there are variations in colour (silver/grey/black) they have proved to be reliable in use with no sheared slot heads on tightening. Subjectively, I feel that they will withstand a higher tightening torque than the Meccano product.
g. Grace’s Guide: There is a website using the name of Grace’s Guide at http://www.gracesguide.co.uk/Main_Page which provides on-line access to various engineering journals – including copies of ‘The Engineer’ and ‘’Engineering’ from the mid 19th Century onwards. These are an absolute mine of topical information on engineering developments through the years and many of the prototypes of models beloved of Meccano modellers can be found within their pages. Searching the site can be a bit torturous but perseverance will reveal much information.