Light Stalk base - Who can make replacement part ?

[TardisDeli]

Hi All, brain puzzle of the day .....

Need Ideas: how can we manufacture a replacement for the little part that breaks at the base of many headlight stalks ????

The part that breaks is a tiny plastic piece, at the base of the light stalk, in the steering column. It moves in response as you click the stalk. Easy to get to by removing steering wheel. This little plastic (like Bakelite) piece at the base of the light stalk cracks with age, so the lever has nothing to click against. It's only about 3/4 inch long, 3/8 inch high, but has several intricate little angles.

Folks are having problems, very few replacement units about. Fortunately we got a whole unit from Mardy, thanks. But Katabic in Ottawa, and others locally need help.

IDEAS ?? Is this something that be done with a CNC, or with Vacuum mold, or some Manly Machine in someone's shoppe ?? Since we only need maybe 50 units, we can't tool up a factory run. Who can draw the part in AutoCad. I could make a plaster 2 piece mold, but then we'd have to find a substance to pour into this mold. I wonder if it needs to be non-metallic. Hmmm....

I am happy to take the piece to someone in lower mainland BC, and deal with the process. But need ideas.

Christine.

[Golf Cart]

Christine,

Yup, that is a nasty lil part. I'm down to one left and the thought had crossed my mind about an alternative.

1) Spending a day at Ralphs searching for an alternative part from another vehicle ( last time I did this , I found enough spare change on the floors to pay for the part I was taking )

2) Get Jay to diaconnect all wires assocciated with the stages and convert the headlights to a North American style pull switch. As far as I can see that busted lil white teflon piece is not needed to actuate between hi and low beam.

If you need a donator , I have 2 you can play around with.

Cheers

[TardisDeli]

Hi Golf Cart,

Yes, Jay did make me a 2 stage pull-switch. Worked great for me as I always remember to turn on the lights manually, then Jay got the complete replacement unit from Mardy.

But my concern is the various people I am PMing who ask for help with wiring issues. If we could make that tiny little part, then everyone would have access to a Proper fix.

For those who ask: I can't install the switch it for others. Involves bypassing automatic running lights. A pull-switch mounted beside the cigarette lighter, pull halfway out to turn on running lights, pull all the way for low beams. On the light stalk, tape the top so you dont turn it; just flick for high beams as usual, and for turn signals as usual. But finding the coorect wires to connect to is an issue.

Jay hopes to post this week the colour wiring codes in the steering column, and photos of how to remove the steering wheel and replace the entire unit. And troubleshooting tips.

So, if we can get the little part to replace, then our Delica Community would be safer and happier.

Golf Cart, I would like your unit spares on loan, if someone has an idea how to make a new part, as I dont have my old unit.... save taking off my steering wheel frequently.

Cheers, Christine.

[fexlboi]

http://www.delica.ca/forum/custom-metal ... -4776.html

Just an idea to get this part done, but we need to create the file at first.

[TardisDeli]

Hi Fexlboi, Do you have a programme to draw the part (ie AutoCad), I remember you posted a beautiful diagram for your dream spare tires and gas tank on a htich. Cheers, Christine.

[fexlboi]

Hi Fexlboi, Do you have a programme to draw the part (ie AutoCad), I remember you posted a beautiful diagram for your dream spare tires and gas tank on a htich. Cheers, Christine.

You can download the a CAD program at their website to create a model.