This is a tex magna lite indicator switch, the leaver had snapped off and replacement switches are rare and fetch high prices. As the original arm assembly was made of an alloy and we felt it was not possible to successfully repair, the picture below shows what remained, the actual arm section has been lost.
We decided to have a go at making a new part out of steel. starting with a length of what used to be known as mild steel, fairly low carbon, easy to forge, drill and file. The end of the bar was sliced to open up and form the U shape then an end formed from a small piece of flat and gas welded in place, there was also some building up for the pivot etc by gas welding.
.
As above the shape was roughly forged out with excess thickness all round, the actual long leaver part was roughly shaped with an angle grinder. The pivot screw hole was drilled and an hour or so spent with a selection of files to bring everything down to the correct dimensions to fit in the switch, the leaver section was guesswork as the original bit was missing so it does lack some detail.
It could have had more time spent on the cosmetic finish, ideally to a standard where it could be chrome plated but in reality the practical option of power coating is the way we went.
