Rudy should be allowed to sleep. With this break, Rudy's eyelids can't close. They
can still be opened wide, and relaxed back to 'awake', but when he goes to sleep
at Midnight, they won't close.
First step (after taking Rudy's front and back face covers off) is to remove his
head from the playfield. Remove and unhook the jaw motor (see
this page), unplug all the connections from his head, remove the four screws
holding his head into the playfield, and he should fall out into your hands. Once
that's done, it helps to take his mouth out of the picture. Unhook the two jaw-closing
springs from the back of his throat, and remove the four screws that hold the wood onto
the bottom of the metal frame. Slide the wood out the back of his head, and set it
aside (it deserves a good cleaning later!)
Here you can see (sort of) the broken plunger, resting in the blue coil. You can
also see the jaw-closing spring I mentioned in the last step, which I hadn't
removed yet. The horizontal white piece is supposed to pull toward the blue coil, which
releases the catch on the vertical white piece. In this view, Rudy's eyes would be
closed, since the vertical piece is all the way up (out of the red coil).
Here's the set of eyelids, removed from the metal frame, along with the two
plunger-and-plastic assemblies. To remove the eyelids from the box sides, first press
the white clips inward through the metal, and then the eyelid pivot should pop through
easily. This would be a good time to clean those eyelids, and the white eyes themselves.
I'm not going to recommend any cleaning solutions - I managed to get these clean with
dry paper towels and some friction.
Two views of the white clip that gets released, to allow the eyelid pivot to escape.
Just like the jaw link unhooks from the
jaw motor gear sector, the eyelid unhooks
from the open-closed plunger with a key through a keyhole. You have to get the vertical
plunger plastic separated from the eyelids to be able to replace the horizontal plunger
plastic. The broken horizontal plunger core is shown in the background - it snapped where
the metal rollpin attaches the plastic to the plunger core.
Next page in the eyelid repair story
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