A dial indicator is an essential tool for any machinist, used for precision tests of concentricity, parallelism, and flatness. My old Teclock indicator has been a trusted companion in my workshop for years. But over time, its crystal face became covered in scratches and scuffs.
It wasn't unusable, but the hazy, blurry view of the needle felt... symbolic. Looking through that opaque window felt like looking into my own uncertain future. And I couldn't stand it.
I could have bought a new one, but I'd grown attached to this reliable old tool. The problem? An exact replacement crystal was nowhere to be found. So, I did the next best thing: I ordered the closest match I could find on AliExpress—one that was 0.1mm too small. The plan wasn't to use it as is. The plan was to make it fit.
The Process: A Game of Millimeters and Patience
This repair required a bit of modification, but with the new parts in hand, I was ready.
Step 1: Disassemble the Bezel
First, I needed to remove the bezel from the indicator's body. There's a retaining spring ring inside with three small bumps. By gently pressing on these bumps with a precision screwdriver while pulling, the bezel comes right off.
Step 2: Reshape the Crystal with Heat
This was the hardest part. The new crystal was 26.4mm, and I needed it to be 26.5mm. My tool of choice: a heat gun.
The trick is to apply heat evenly while gently pressing and shaping the plastic with your fingers to expand it just enough without melting or deforming it. It's a delicate process that relies entirely on feel.
I have to be honest: I failed twice before I finally got it right on the third try.
Step 3: Installation and Reassembly
With the crystal perfectly resized, it snapped into the bezel with a satisfying 'click'.
And while I was at it, I gave the grimy dial face a good cleaning with some alcohol.
The final step was to carefully press the bezel back onto the body, ensuring the spring clips engaged properly. The repair was a success.
For those who want to see the full process, here is the video:
The Final Result: A Clear View, For Now
The indicator looks almost new. The needle and markings, once hazy and dim, are now crystal clear. With 24 spares left, I'm set for a long time. Who knows, maybe it will become a family heirloom passed down through generations.
If only our own opaque futures could be seen as clearly and cleanly as this measuring tool. For now, I can only hope the days ahead will be a little brighter than those behind us.
