26/27 Ignition Switch

[BarnesvilleT]

My '26 original ignition switch tumbler broke at the back inside and I replaced it with an aftermarket one.
It works but when in the Batt position it is right on the edge of making contact and while driving
it will vibrate and move just slightly and shut the engine off. I can't turn the key any more. I have 20volts from my magneto but when I
switch over it seems like it is not making a good contact there as well. Engine stutters some so I switch back
to Batt. It is happening more regularly and I just have to hold the key to make contact again.
We did have to do a lot of filing and fitting to make the new switch work so I am thinking the aftermarket tumbler
is not a very good reproduction. Has anyone bought one of the aftermarket 26/27 oval panels with the switch installed
and had good working results. They seem to be going for about a $100 bucks. I have looked on line for an original but they are hard to find and some are in pretty bad shape. Thanks,
Bill

[jiminbartow]

It is always best to do everything you can to preserve the original parts, as modern reproductions are never as good as the original. Have you tried to repair the original tumbler cylinder with a 2 part epoxy putty. I prefer “Aluminum Devcon”. from McMaster Carr. I get the 3 lb. box 2 part putty. Mixed 4 parts epoxy to 1 part activator. Www.McMaster.com. You can repair the crack by applying a thick ring of epoxy around the cylinder. There is plenty of room inside the switch handle to accommodate a thick ring of epoxy putty applied around the cylinder over the crack. You may want to V out the crack a little and sand the area to be repaired to increase adherence of the patty to the pot metal cylinder. Clean good with lacquer thinner to remove any lubricant and dirt. Be careful not to get any putty inside the tumbler slots. Jim Patrick

[Dan Hatch]

Bill: Your neighbor Ben Martin is who you need to talk to. Dan

[TRDxB2]

My '26 original ignition switch tumbler broke at the back inside and I replaced it with an aftermarket one.
It works but when in the Batt position it is right on the edge of making contact and while driving
it will vibrate and move just slightly and shut the engine off. I can't turn the key any more. I have 20volts from my magneto but when I
switch over it seems like it is not making a good contact there as well. Engine stutters some so I switch back
to Batt. It is happening more regularly and I just have to hold the key to make contact again.
We did have to do a lot of filing and fitting to make the new switch work so I am thinking the aftermarket tumbler
is not a very good reproduction. Has anyone bought one of the aftermarket 26/27 oval panels with the switch installed
and had good working results. They seem to be going for about a $100 bucks. I have looked on line for an original but they are hard to find and some are in pretty bad shape. Thanks,
Bill

I think I know what you problem is. I need to take some photos to explain the issue. Will do Today
Was the filing/fitting you did limited to getting the end of the tumbled bump to fit into the small disk?

[BarnesvilleT]

That is correct. It would not fit. We got it fo fit but not sure where to go from there. It does not seem to turn to the left
all the way.Not sure it it matters but we think we might have also put the tumbler in 180 degrees from what it was.
I am trying to get Ben's number and try Dan's suggestion.

[TRDxB2]

That is correct. It would not fit. We got it fo fit but not sure where to go from there. It does not seem to turn to the left
all the way.Not sure it it matters but we think we might have also put the tumbler in 180 degrees from what it was.
I am trying to get Ben's number and try Dan's suggestion.

I have repaired many switch a well, but not as many as Ben.
There are variations in the backing plate as being a clip or pin type. That will not make a difference. I have included pictures showing the differences in the tumblers and also the cups/cages that hold the tumbler
First guess is that the switch is caught on part of the cage red circles and not getting to the stop

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Another possibility depends on if you have an old backing plate that might have an issue with the contact area preventing it from settling into position

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Here are some differences in the tumblers
1 the end of the repro that goes into the small contact ring for selecting MAG or BAT is slight wider & thicker
2 one edge needs to be trimmed to allow it to rotate from side to side to get to the stops.
3 the lengths & diameter are different. The diameter prevents it from fitting into the cage
4 the design of the switch does not hold the wafers in place when the key is removed. As a result if the key is removed & the tumbler is turned upside down the wafers will fall out. A specific cage is designed for this

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There are two types of cages. One type (two variations) is for tumblers that would have wafers fall out if the switch was turned upside down and catch the wafers. The other is for tumblers that were constructed to not allow the wafers to fall out
The one on the left is the catch type. Note that each is orientated properly: Tumbler in cage and cage in cup with respect the the cup

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[BarnesvilleT]

That is great information. I wish I would have started the thread before we attempted to
use the aftermarket tumbler. I think that the cage on mine is at fault. I will pull the switch panel out
and have a look an compare to your photos. I have a friend looking to see if he has a switch that I
can use or get fixed. Going to try to get a hold of Ben as he is only about 40 minutes from me.
I found his number in an old thread.
Will keep you posted.

Bill

[TRDxB2]

That is great information. I wish I would have started the thread before we attempted to
use the aftermarket tumbler. I think that the cage on mine is at fault. I will pull the switch panel out
and have a look an compare to your photos. I have a friend looking to see if he has a switch that I
can use or get fixed. Going to try to get a hold of Ben as he is only about 40 minutes from me.
I found his number in an old thread.
Will keep you posted.

Bill

There are a set of components that the after market tumble fits in. May not be available anywhere & anymore

[J1MGOLDEN]

Ben's Number is 770-938-3376

He lives at 4396 Lavista Road, Tucker, GA, 30084

He is still recovering from some health issues, but he will probably have some time to visit with you.

He does not do Email.

[J1MGOLDEN]

One of those three pins will often break out of the black plastic, if you open the back to discover or repair your problem.

That old, pressed paper back piece is actually stronger, which is some sort of a miracle.