You are right, I also used a modelers razor saw to cut the shaft.
Instead of bending the lock washer, I used a Danco #8 O-Ring
(from Lowes) to retain the switch key. It fit snug enough you
will never have to worry about the key falling off while fiddling
with the switch and when the front cover is mounted, the thickness
of the O-Ring will provide about 1/32" of compression against the
NA1MH, photo below...
On 1/2/2017 11:10, Jim Sheldon wrote:
I agree 100 percent 1/4" is too much. I only cut 3/16" off mine
and measured it very carefully. I cut it with one of those X-Acto
razor saws model makers use. If I'd taken a full 1/4" off it I'd
be looking for a new switch along with the attendant hour sucking
the solder off those terminals to get the switch out. I think
3/16 is going to be hard to get exact for many of the people, but
any more than that is going to be problems.
I also didn't like the fact that the front panel doesn't set down
tight against the switch. If you don't bend that internal tooth
lockwasher enough, the switch's rotational stop will jump out and
then you really have to take the panel off again to put it back
where it belongs. I'm thinking I might try and find a thin
control nut and lock it down, leaving the nut off the top of the
panel if it becomes necessary.
Jim - W0EB
David Martin - NA1MH - Mountain Home, Ar.