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ross kowalski
Grand Master
Username: cdfpw

Post Number: 793
Registered: 11-2015
Posted on Sunday, 27 May, 2018 - 09:59 am:   Edit PostDelete PostView Post/Check IP

The little arrow lights on the dash stopped blinking recently. The marker lights on the car work but the dash ones help you remember you left them on.

I found the culprit. A bodged repair on the switch assembly.



Turns out the other contact had a crack too.

Here is the plate in the steering column.

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ross kowalski
Grand Master
Username: cdfpw

Post Number: 794
Registered: 11-2015
Posted on Sunday, 27 May, 2018 - 10:01 am:   Edit PostDelete PostView Post/Check IP

Here's how to make replacement contacts.


First go in your shed and find an old switch.



Crack it open to reveal the contacts.

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ross kowalski
Grand Master
Username: cdfpw

Post Number: 795
Registered: 11-2015
Posted on Sunday, 27 May, 2018 - 10:03 am:   Edit PostDelete PostView Post/Check IP

Then remove the bad contacts from the plate by shaving off the tops of the brass tube rivets.

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ross kowalski
Grand Master
Username: cdfpw

Post Number: 796
Registered: 11-2015
Posted on Sunday, 27 May, 2018 - 10:40 pm:   Edit PostDelete PostView Post/Check IP

Separate the diner springs from the switch mechanism. I didn't have any tools so I nicked the steel backing plate at the beginning and end of the cut then bent it back and forth to form a crack at that line. Cracks always form from little Nick's so if you make the nicks yourself you can control the cracking.



The finished cut.

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ross kowalski
Grand Master
Username: cdfpw

Post Number: 797
Registered: 11-2015
Posted on Sunday, 27 May, 2018 - 10:45 pm:   Edit PostDelete PostView Post/Check IP

My goal was to do this as one might mend it roadside with just the tools in the toolkit. That's probably possible, but because no one would ever NEED to fix their dashboard turn indicators, and the only file in the RR toolkit is a disaster, I folded and grabbed a proper soldering gun and swiss file.




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ross kowalski
Grand Master
Username: cdfpw

Post Number: 798
Registered: 11-2015
Posted on Sunday, 27 May, 2018 - 11:00 pm:   Edit PostDelete PostView Post/Check IP

The switch contacts tops were pretty close in shape from the start.



The contact portion at the bottom were not very close in shape.



The thickness of the RR part was a lot thinner than the replacement.



I filed the contact portion to shape and thinned it. I gave it some distal taper leaving the anchored end full thickness to prevent bending ( and eventual cracking ) in that area. A well known trick in some circles is to file each course over a surface at a slightly different angle to ensure even filing.



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ross kowalski
Grand Master
Username: cdfpw

Post Number: 799
Registered: 11-2015
Posted on Sunday, 27 May, 2018 - 11:06 pm:   Edit PostDelete PostView Post/Check IP

An original and some replacements in the works.



Having already given up on trying to make this a roadside tool only affair. I got or the drill poked some holes and bolted on the contacts.


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ross kowalski
Grand Master
Username: cdfpw

Post Number: 800
Registered: 11-2015
Posted on Monday, 28 May, 2018 - 12:37 am:   Edit PostDelete PostView Post/Check IP

Works a treat
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Patrick Ryan
Grand Master
Username: patrick_r

Post Number: 1912
Registered: 4-2016
Posted on Monday, 28 May, 2018 - 01:25 am:   Edit PostDelete PostView Post/Check IP

That is an amazing step by step job mate.

Nothing gets in your way does it!!

You look like you had fun with this problem.
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Omar M. Shams
Grand Master
Username: omar

Post Number: 1538
Registered: 4-2009
Posted on Monday, 28 May, 2018 - 04:45 am:   Edit PostDelete PostView Post/Check IP

Great Job Ross.
Also most entertaining and ingenious
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Patrick Lockyer.
Grand Master
Username: pat_lockyer

Post Number: 1883
Registered: 9-2004
Posted on Monday, 28 May, 2018 - 05:28 am:   Edit PostDelete PostView Post/Check IP

Ross, nice work there, very rewarding when completed and working.
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ross kowalski
Grand Master
Username: cdfpw

Post Number: 801
Registered: 11-2015
Posted on Monday, 28 May, 2018 - 01:09 pm:   Edit PostDelete PostView Post/Check IP

Thanks,

I figured finding one would be harder than a fix on the old one. Also, quicker and cheaper.

I forgot to thank my wife who provided the swiss file which was a absolute pleasure to use.
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Vladimir Ivanovich Kirillov
Grand Master
Username: soviet

Post Number: 919
Registered: 2-2013
Posted on Monday, 28 May, 2018 - 06:32 pm:   Edit PostDelete PostView Post/Check IP

That was a supercool repair Ross. I now award you the title "master tinkerer". A repair shop could have fixed the problem for you with an invoice that would have made your wallet tremble and yelp.

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