HW-101 Lever

[Stu Lyon]

One of the things we are overlooking in this lever casting is that Heath
used two differant designs on the lever.

The SB-401, -301 (and maybe -400) used a #4 Allen-head set screw and a
molded-in metal insert. The shaft was 1/4" full round. (Ref. SB-401 manual,
pg. 86, Detail 5-8A)

The SB-101 (and others) used a loose metal insert and a notched shaft. You
placed the insert on the shaft and pressed the plastic lever on the knurled
insert. You then removed the partial assembly and pressed the insert in with
a nutdriver or similar. This implies that a) you would need a loose metal
insert and b) the design of the metal insert is complicated.  (Ref. SB-101
manual,pq.79, Detail 3-24A).

I have a Drake TR-4 that uses plastic knobs with no inserts. One day I
tighten a knob too much and the knob neatly split in two. I think the metal
insert is essential.

I hope someone can solve this problem but it's not going to be easy.

73, Stu W6CUX
Winnetka, CA

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