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I have a Thomas Symphony Royale 782 with the rack portion of the rack and pinion volume control broken. Where might I find this component?

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  • Warren Godfrey Feb 03, 2010

    Thanks for the response, but it is strictly a mechanical problem. One end of the piece I need has a pivot point that bolts to the outside edge of the volume pedal at it's top right hand corner. I would guesstimate the remainder of the piece to be about 5 inches long (I don't have all of the pieces from the old one.) It is slightly curved and has teeth on the underside that mesh with the gear mounted on the end of the potentiometer shaft.
    As a retired woodworker, if I can't find the actual part I will have to fabricate one from maple using the bandsaw. I would much rather have the factory part though if at all possible. The plastic won't move when there is a change in humidity or temperature.

  • Warren Godfrey Feb 04, 2010

    The brass rack & spur gear seems like it could be the perfect solution, but I'm curious as to how much of a bend the rack will take without distorting the meshing of the rack and spur gear. The one piece that I have left of the original rack is long enough to calculate that the arc it presents is one created by a seven and one eighth inch radius at the crown of the teeth (teeth are on the outside of the arc). Is it reasonable to expect that one could bend a section of the indicated rack to such an arc without adversely impacting the meshing of the two pieces?

  • Warren Godfrey Feb 04, 2010

    I also meant to correct a significant typo on my original inquiry, not that it means a lot at this point, but the Model # of the Thomas is a Symphony Royale 871 not the 782 indicated. Also, I would hope that there is a range in diameters of the spur gears for any rack. The organ is not where I can measure it right now, but I believe that the gear currently on the shaft has a diameter around 1 1/2". Obviously the diameter is important in terms of the number of revolutions the potentiometer shaft will take as the rack travels it's entire length.



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If it is the potentiometer that is broken, it is likely an AllenBradley "J" style pot.

Here is Digikey site for J pots. Choose resistance to match. You may need to check if it is an audio taper as well. The site should have them as well.

Posted on Feb 02, 2010

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  • Fred Yearian Feb 03, 2010

    I was afraid that it MIGHT be the gear rack. Making one of maple will NOT hold up to the wear of the gear.

    Now here is what we do: You can buy gear rack, including brass,


    I would probably select the BSR1-300 which should be about 12 inches of 8 teeth per inch...(dimensions there are metric) I would also get a spur gear to match from them with a 1/4 inch hole or one you could modify to fit the pot.

    The brass rack you could warm with a propane torch and curve a bit as needed. You could drill or attach it as needed.

  • Fred Yearian Feb 04, 2010

    The brass rack could be thinned in depth a bit and sometimes one can make cuts to allow it to bend a bit... Heat of course would help it bend. There are other options on the site, however they all seemed much longer and more expensive.

    Yes, the total travel number of teeth and the diameter of the gear is important to get close.

  • Fred Yearian Feb 04, 2010

    Two more ideas:

    This is a 5 inch gear... MAYBE you could cut it down to make the rack?

    Next idea is to use a ladder chain and sprocket with a spring.



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