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djkeev
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Location: Reading Pennsylvania
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John Moxon 
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djkeev
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Joined: September 30, 2007
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Location: Reading Pennsylvania
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djkeev
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djkeev
Samba Moderator
Joined: September 30, 2007
Posts: 32989
Location: Reading Pennsylvania
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 Posted: Mon Mar 26, 2018 4:52 am Post subject: Re: Dash Switch Escutcheon Tool |
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Well, the air fitting does not fit over the headlight switch shaft.
Easy enough, drill it out!
Find out what size hole I need.......
Select the drill bit.......
And drill it out......
But wait!
The drill bit is NOT cutting, it is just spinning on the surface!
Oh, Crap!
This fitting is hardened steel!
OK..... we can fix that. Hardened steel is simply rearranging the molecular structure of steel by using controlled heat and cooling.
A little heat to red hot will fix this pronto!
(I removed it from the vise because the massive iron jaws of the vice would be a HUGE heat sink and it would take FOREVER to heat that nipple up to red hot while clamped) it's pretty once the metal reaches red hot.
While still red hot back to the vice and I drill the hole....... it pops through like soft butter!
I'll go get some breakfast while this thing cools slowly in the vice. Quench it too quickly and the hardness returns which will make the next step of file work more difficult.
Dave
_________________
Stop Dead Photo Links how to post photos
Ghia
http://www.thesamba.com/vw/forum/viewtopic.php?t=392473
Vanagon
http://www.thesamba.com/vw/forum/viewtopic.php?p=6315537#6315537
Beetle
https://www.thesamba.com/vw/forum/viewtopic.php?t=482968&highlight=74+super+vert
Last edited by djkeev on Mon Mar 26, 2018 4:47 pm; edited 1 time in total |
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Figment
Samba Member
Joined: October 27, 2016
Posts: 218
Location: Connecticut, USA
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| Posted: Mon Mar 26, 2018 5:26 am Post subject: Re: Dash Switch Escutcheon Tool |
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Surely I'm not the only one who uses a careful hand and a pair of fine needle-nose pliers for the job?
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'71 Ghia coupe |
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kman
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Joined: November 04, 2005
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Location: Michigan
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djkeev
Samba Moderator
Joined: September 30, 2007
Posts: 32989
Location: Reading Pennsylvania
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| Posted: Mon Mar 26, 2018 6:10 am Post subject: Re: Dash Switch Escutcheon Tool |
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I got the 4 way one off easily using a US Nickel and a pair of pliers. There wasn't a shaft to work around.
The others were so tight and so corroded that they were not yielding to needle nose pliers, a drift and small ball peen hammer worked fine until the switch became loose and then I needed a third hand to hold the switch as the other two hands worked the drift and hammer. The threads were tight almost all the way out.
Anyway, after a Piece of toast (buttered of course!), 2 eggs over easy, a splash of coffee and a glass of juice (Grape) and I'm back in the garage.
First, Does the drilled out fitting fit over the shaft?
Yes it does, but the entire assembly is too long and the turn signal lever is in the way....
Simple fix, out comes mr. hacksaw....
A little file work to remove burrs inside and outside.....
Here is the escutcheon from my 4 way switch to use as a pattern for fitting.
Hack saw down both sides to the right and left of center leaving a tang wider than the escutcheon slot......
Cut off the outer part to leave the center tang.....
Using the Escutcheon as a guide I filed the tang to fit, both width and angle....
To rotate the tool I could use a pair pliers or vice grips, but that's primitive!
I figured I'd make a 12mm wrench fit, it is a German car after all and I'll be carrying metric tools in my highway kit.
I could go fancy and make a hex for a socket but I wimped out and made two flats 180* from each other.....
I Tried it on the Headlight switch and then the wiper switch.
The nut was SO TIGHT on the wiper switch I had to use a hammer and drift to break it loose but once loose it spun right off easily using the tool.
Honestly, with stopping to stage and take photos this took me a total of 15 working minutes to make. Without documenting the steps? probably 10 minutes.
It has taken me longer to write this HOW TO than it took to make the tool.
I'll throw it in my travel kit.... just in case.
Just a note, it would probably be best to have a little larger diameter stock to make the tool from. Mine catches fine..... but only on the inner part of the slots. A larger diameter would give a more secure "bite" to the tool.
Dave
_________________
Stop Dead Photo Links how to post photos
Ghia
http://www.thesamba.com/vw/forum/viewtopic.php?t=392473
Vanagon
http://www.thesamba.com/vw/forum/viewtopic.php?p=6315537#6315537
Beetle
https://www.thesamba.com/vw/forum/viewtopic.php?t=482968&highlight=74+super+vert
Last edited by djkeev on Mon Mar 26, 2018 4:51 pm; edited 1 time in total |
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djkeev
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Location: Reading Pennsylvania
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BulliBill
Samba Member
Joined: July 09, 2004
Posts: 4776
Location: St Charles, MO
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| Posted: Mon Mar 26, 2018 1:06 pm Post subject: Re: Dash Switch Escutcheon Tool |
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Nice work Sir! Great "how-to" also! Thanks for sharing! You are my kind of VW enthusiast...
Bill Bowman
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I'm looking for these license plate frames for my fleet:
Coeur D'Alene - Lake Shore Volkswagen
Mission VW - San Fernando
Thornton VW - Stockton
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kiwighia68
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Joined: October 20, 2013
Posts: 2938
Location: Auckland, New Zealand
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| Posted: Tue Mar 27, 2018 4:29 pm Post subject: Re: Dash Switch Escutcheon Tool |
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| Figment wrote: |
| Surely I'm not the only one who uses a careful hand and a pair of fine needle-nose pliers for the job? |
You are not alone brother.
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Festina lente - hasten slowly
1968 Ghia named Emiko
Resto completed Dec 2015 |
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djkeev
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Max Welton
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xzener
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| Posted: Tue Mar 27, 2018 7:11 pm Post subject: Re: Dash Switch Escutcheon Tool |
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I feel fortunate to have removed mine with ease... Don't recall how I removed them, but they certainly were not stuck. Seems like a lot of work to remove/install a couple parts... I probably would have bought the tool. Well done.
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My 70 beetle was totaled Now to build the Ghia I always wanted. Rest in peace Ruby, I will miss you. Hello <insert Ghia name here>! |
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djkeev
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iowegian
Samba Curmudgeon
Joined: February 16, 2005
Posts: 9946
Location: Somewhere between Dubuque and Keokuk
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| Posted: Wed Mar 28, 2018 7:55 am Post subject: Re: Dash Switch Escutcheon Tool |
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| djkeev wrote: |
I am a huge believer of having the tool for the job.
Many people look at disbelief when they see that I have 30 some odd hammers.
16 of them hang above my bench for frequent use.
Each one has a unique use. Sure you could go "one size fits all" but the given task is so much easier and done more efficiently when using the proper tool.
Dave |
Ah, yes.
When all else fails, get a bigger hammer.  |
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djkeev
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Glenn
Mr. 010
Joined: December 25, 2001
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| Posted: Wed Mar 28, 2018 9:28 am Post subject: Re: Dash Switch Escutcheon Tool |
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Dave, wish i saw this sooner. I would of lent you the tool if you covered shipping both ways.
_________________
Glenn
74 Beetle Specs | 74 Beetle Restoration | 2180cc Engine
"You may not get what you pay for, but you always pay for what you get"
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עַם יִשְׂרָאֵל חַי |
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djkeev
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Figment
Samba Member
Joined: October 27, 2016
Posts: 218
Location: Connecticut, USA
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| Posted: Wed Mar 28, 2018 12:23 pm Post subject: Re: Dash Switch Escutcheon Tool |
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A kid gets a summer job as an apprentice at a boatyard, working beside a fastidious old salt. Using The Correct Tool For The Job is lesson #1.
It was also lessons #2 through 37, but eventually the kid got the idea.
It was one of those summers.
On the last day before school resumes, the kid walks into the workshop.
"Hey, Chief, gimme a wrench!"
What kind of wrench? we have hundreds of wrenches in this place!
"The HEAVY kind, I need to use it as a hammer..."
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