making crossover indicator switch screws

Discussion in 'How To' started by Diddymen, Apr 7, 2013.

  1. this next bit, although simple enough had me really pleased,

    I have been putting off re fitting my crossover indicators/wash/wipe switches because I had lost all of the screws :oops:

    ......and as we all know you cant seem to buy them new as they have very small heads to fit down inside the housing, so you have to go second hand if you can find them ....which will probably be rusty

    So I had been pondering what to do, I could get some turned down on a lathe ....which meant waiting for them to be done, calling in favours etc, or I could try to grind them back using a grinder - fiddly and I would probably launch a few across the garage before I had made enough....and they probably wouldnt turn out that neat ......so heres a 'how to' for the solution I came up with

    I would turn them down my self using tools I had to hand :)

    so, I needed 3 files - one large course, one medium and one fine ....and a battery drill (and some screws of the right thread of course) I believe the switch mounting ones are 4mm, and the ones holding the housings together I initially thought were 5mm, but a BA thread seemed to fit better

    so here are my files

    [​IMG]

    next fit the screw into the chck of the drill, being careful to get it centred and not damaging the threads

    [​IMG]

    then clamp the large course file in a vice and use your drill to to start turning down the head of the screw against the flat of the file

    [​IMG]

    take your time, if you put too much pressure on, then the screw will fly off into a dark corner never to be seen again ....if you do find it you will probably have damaged the threads so will need to run it through a die nut to clean them up at the end.

    keep periodically checking the diameter of the screw head until it fits the housing

    once it fits, use the medium file to clean up the head a bit more and remove the deep scratches from the course file (you can hold the medium file by hand for this)

    [​IMG]

    using the same file chamfer the edges to take off any burrs by holding the medium file at an angle to the top and bottom faces of the screw head

    [​IMG]

    then use the small needle file to clean any burrs out of the slot in the screw head

    and you should be left with an even, neat screw :)

    [​IMG]

    do the same with the housing fixing screws if necessary

    and here is the finished item

    [​IMG]
     
    Last edited: Oct 2, 2017
  2. Simple but effective Diddy, Great how too!
     

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