Easy repair tips for making it better than original - Saab 900 Bulletin Board - Saabnet.com
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As Name Left Blank said.. this is an easy repair with a dremel. You can make it better than original by taking care of a few details (easiest if you have access to a drill press):
Remove the switch from the car.
The brittle plastic cover is held on with "rivets" formed from the aluminum body. It is not designed to be taken apart, but you can. You need to drill the "rivets" out, but the secret is to only remove enough material that the plastic is released (just the top bit of the rivet). Don't try to drill out all of the rivet!
Next cut or grind the rivets off flush (dremel, grinder, whatever, this is easy to do).
Grind the roller tracks to square them off again (dremel).
Mark with the cover where the holes should go. Then drill tap holes for 2-56 in those locations (ideally #50, 70 thou.. I think I got away using a 5/64" bit which is 0.0781" as that is < the major diameter but < minor diameter... 1/16" is < minor diameter so probably wouldn't work - see data sheet link below). I use 3/8" 2-56 flathead screws, and because aluminum is so soft and the thread pitch is so fine, you do not even need to tap the holes - the screw will self tap...
I also gently countersink the outside of the plastic for the flatheads. You want them flush and not to strain the plastic or crack it.
Then reassemble. looks better than new! [will post pictures as soon as I find them]
screw tap/thru size table
->Posting last edited on Sat, 8 Dec 2018 19:03:50.
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