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In this particular lock, the cage had snapped towards the back end where it engages with the switch unit. Because of the shape, it wasn't possible to simply drill and pin the end so a complete new endpiece had to be made.
The way I decided to proceed at this point was to make up a brass replacement for the end, then file flats on it and the cage and rivet them together. First step was to turn some brass to the smaller diameter of the cage end, then cut it longitudinally to make a slightly-more-than half-round piece:
Next, using the wonderful invention that is the diamond-coated cutting disk, cut the end to form the "T" shape that fits the switch:
The new piece is then filed to form a slanted face, and the cage filed to match. The slant is to avoid thinning the die-cast original more than is needed to make a neat joint. The two parts are then drilled and rivetted together:
Finally, it's just a case of reassembly (reverse of disassembly) and refit to the car. Another job jobbed! Previous page      HowTo Index |