I'm going to use information gained from maintenance and repair threads here on TDF, on Our Doll Community and on the UK Doll Forum to do this task so thanks to all those who've contributed their modification and maintenance posts and threads.
Although the upper pivot can be reached by rolling the doll's neck silicone down with the head still in place it is a lot easier to do by removing the head completely. That's what we'll do here.
Basically we are going to drill out the Pop Rivets and replace them with a bolt and nylock nut.
*Note As BoyToys are made in the USA their nuts and bolts are in imperial sizes, I will be replacing the Pop Rivets with locally (UK) sourced Metric nuts and bolts so will need both types of wrenches/sockets.
Tools required.
- Socket wrench/Ratchet
- 7/16 wrench
- 7/16 socket
- 10mm socket
- Allen Key for M6 Bolt
- Pliers
- Electric Drill and bit
- Phillips Screwdriver
- M6 16mm Dome/Button head bolt x2
- M6 Nylock nut x2
- Suitable washers x4
- Cleaning Cloth
- Acetone.
Next unscrew the 3 screws that secure the skullcap.
Remove the skullcap and place in a safe area.
Here we can see the two 7/16AF lock nuts that secure the head to the mounting bracket.
Insert the 7/16 wrench under the doll's head mounting bracket and secure the head of one of the mounting bolts, using the socket wrench and 7/16 socket remove the locknut and washer, do the same for the second, supporting the doll's head while you do.
The head will now lift clear of the support bracket. Place the nuts, bolts and washers somewhere safe, we will be reusing them later.
This is the top section of the upper neck pivot, with the cavity for the end of the oral insert below.
Using the handles of the pliers, or your fingers, push the neck silicone downwards on one side.
We can now clearly see the offending Pop Rivet.
While securing the neck silicone out of the way of the pivot, drill out and remove the Pop Rivet and washers.
Fit a M6 dome head bolt and one washer through the hole from the inside facing out. (We are using a dome head bolt and doing this to minimize the amount that protrudes into the oral insert cavity once everything is back in place).
Using the Allen key and socket wrench with 10mm socket, secure the other end with the Nylock nut and another washer.
Now remove the Pop Rivet and washer from the other side of the mount, fit the M6 domehead bolt and nylock nut.
Tighten both nuts until you can no longer pivot the bracket by hand, they need to be quite tight as the weight of the head hinges on these pivots. We can make small adjustments later.
Using the cloth and acetone clean up any swarf and remains of the pop rivets from around the neck pivots and inside the cavity.
Adjust the neck silicone back into place.
Refit the head to the mounting bracket using the 7/16AF nuts and bolts you removed earlier, ensuring the nuts and washers are on top.
Check your doll's head now pivots and stays in place when unsupported, if it requires adjustment, pull down the silicone at either side and using the allen key and socket wrench, tighten or loosen the nuts until the desired tension is obtained. It should still be tight at this point as the skullcap and face will add considerable weight to the head.
Refit the skullcap and secure to the doll's head.
Refit the oral insert.
Refit the face.
Test for full movement of the head and ensure it stays in place when not being supported. Make small adjustments to the tension by pulling the neck silicone down and adjusting the nylock nuts.
Once you are happy with the tension refit the eyes and hair.
Job Done. No more floppy head.
CT
