Products & Service
Brandnew 21st Century Replacement Parts
Rounded Out "D" Shaped Spindle
A rounded out "D" shaped spindle in the plastic center is a common problem on the upper back panel switch. The male end of the upper back panel gear box that fits into the spindle is composed of steel. Over a period of time the steel starts to round out the plastic center and makes the adjustment settings virtually impossible. Certified Rebuilders' steel "D" shaped inserts are CNC designed with over 25 sharp teeth around the circumference and a depth of a quarter of an inch. After the old rounded out plastic "D" shaped spindle is prepared, the steel insert is pressed into the body of the center as illustrated below.
Pictured above is a center section that has been rounded out. Notice that the "D" shaped center is almost nonexistent. The steel male end continuously wears against the plastic center and ultimately eliminates it leaving the switch inoperative.
Pictured above is the center spindle with the new steel insert installed
Stainless Steel Spindles
Just released, brand new stainless steel center spindles. These spindles are beautiful and will out last your car. These CNC designed units have already received high reviews from Thunderbird retailers across the US. If your old plastic center spindle is destroyed, this will save the day. Most customers are now requesting their switch have the new stainless steel spindles installed regardless of the condition of their old plastic spindle.
Broken End Cap Thread Housings
Broken plastic end caps adjustment blocks are usually the result of over tightening or the brass insert, used in some switches, is pulled through its plastic mount. The aluminum repair blocks that we use are CNC machined designed with the correct diameter machine screw thread. With the broken or damaged mount removed, the end cap is set in a jig and pre drilled to the correct position for the new blocks. The new aluminum blocks are secured with two number 2x56 stainless machine screws, with lock-tite, recessed into the end covers as not to interfere with proper mounting of the switch. They are far superior to the original plastic. They will not strip out from over tightening like the plastic. Look at the pictures below.
The picture below shows two end caps prior to repairs. Note the end cap on the right where the brass center has pulled through the plastic housing. The brass inserts pull through the plastic and break away. The new aluminum blocks eliminate this condition.
Here's a close up of a broken end cap
Repaired end cap
Repaired end cap hand filed to the contour of the switch half
Destroyed Round End Caps
Damaged, broken, irreparable end caps are now being replaced with brand new parts manufactured from acetal delrin. This material is far superior in strength to the original plastic. Notice in the picture below the two rear end caps. The two new end caps pictured are fitted with our aluminum adjustment blocks.
Worn Center Torsion Spring
The center torsion spring holds the center section tight against the "D" shaft when rotating on the gear box. After 35 years this spring becomes worn, bent, rusted and not able to hold the center properly. Look at some of the center torsion springs in the picture below. These are actual torsion springs removed from switches. We have contracted with a spring and wire manufacturer reproducing these springs using 21st century technology making these replacement springs better than the original designs manufactured in the 1960's
Notice the five bent out of round springs
The spring installed on the switch center is brand new with the correct tension preset and wing span
Here's a close-up of the new torsion spring
Worn Electrical Contact Compression Coil Springs
There are five internal compression springs that hold the electrical rollers in place against their electrical contacts. After 30 some odd years of being in the compressed state they will loose their ability to hold the rollers tight as the internal holders rotate inside. Consider the effects of time on your vehicles front coil springs and your bed's box spring.
In this picture below you'll notice six coil springs at the top of the picture and one at the bottom center. The six on top are actual springs removed from switches that have been restored. Notice the effects of time and wear. The center spring on the bottom is brand new. The new spring has been designed with the correct compression rating to last another 35 years.
Internal Electrical Contact Rollers
There are five internal contact rollers in the Tbird switch and six in the Lincoln switch. Most of the switches that are sent in to restore are missing a number of these rollers or over time the rollers have become distorted. We have brand new rollers available to replace missing or defective rollers. Pictured below is a sampling of defective rollers with two new rollers pictured at the bottom.
A sampling of new contact electrical rollers is pictured below