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Date: Thu, 20 Mar 2003 07:14:04 +0000
From: Grunff <>
Subject: Re: No high beams on 1987 9000

Abdallah wrote: > if it is indeed the melted cam, i've seen other solutions posted elsewhere, > but this is how i solved it. if you are handy at epoxy, have a cutting > knife, a piece of <secret ingredient> plastic laminate (you know, the stuff > kitchen counters are made of - you should be able to get samples from any > cabinet manufacturer) </secret ingredient>, a small metal file (emery cloth > may do) and an afternoon to spare, extract the assembly as described and > take out that melted nylon cam part to rebuild it. > > what i did was to fabricate a small square cam from a double thickness of > the plastic laminate (glued together with epoxy), drilled a small hole > through it and epoxied it into position on the nylon rod. of course you > have to cut off the old square first, so you'll have to mark its orientation > accurately so it activates the metal toggle switch correctly. a bit fiddly, > but if you get familiar with how it all works first, then its a snap. the > square cam is designed to go through a full rotation every eight flics of > the dipper switch. it alternates between sitting flat on a reciprocating > metal toggle (lo-beam) and sitting with a corner against the flat metal > "spring" (what do you call that thing?) that moves the metal contact > (hi-beam). > > the reason i used the plastic laminate is that i figured it would not melt > (resists hot pots on the kitchen counter!) nor would it transfer heat to the > epoxy or the nylon rod since its an insulator. i've had the rebuilt switch > in the car for over six months now and it hasn't "mis-fired" yet! That's a good idea - I'll try that on the next one that fails. -- Grunff

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