Author Topic: Douglas Dragonfly make a Switch contact tab  (Read 225 times)

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Offline BrmBrm

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Douglas Dragonfly make a Switch contact tab
« on: 10 Jan 2019 at 20:20 »
Next phase of the Dragonfly switch replacement. A contact tab.

I need to make the contact tab that goes onto the switch mounting stud.
That is the one that would be contact number 9.
On the circular central switch area there are different contact bands.
Which of these should contact 9 bear against?
It presumably fits on the stud under the nut?
What shape should it be?
Like one of the other contact tabs?
Any help appreciated
Many thanks.
« Last Edit: 11 Jan 2019 at 09:09 by BrmBrm »

Offline andy1303

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Re: Douglas Dragonfly make a Switch contact tab
« Reply #1 on: 13 Jan 2019 at 20:33 »
I had a look on my bike today, and while it was obscured by the rest of the switch, it looked like there was a crimp ring terminal on the switch and I think it was on position 9. Mine was one of the awful blue insulated crimp variety, but I'll probably replace it with a proper brass ring terminal at some point. Would that be what you're looking for?

Andy

Offline Red

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Re: Douglas Dragonfly make a Switch contact tab
« Reply #2 on: 15 Jan 2019 at 12:43 »
Hi Brm

Terminal 9 is connected to the resitor for the ignition warning light in the Miller ammeter. On my Dragonfly I don't have the Miller ammeter or the ignition warning light so I disregarded this connection. The stud for teminal 9 is also used for one of the small "L" clamps which secure the switch in the headlamp housing. Therefore if you are going to run a wire from terminal 9 to the ignition warning light resitor you will need to make sure the "L" clamp is well insulated from the inside of the headlamp housing otherwise when you switch on the igntion you are likely to get a short to earth.

Roy

Offline BrmBrm

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Re: Douglas Dragonfly make a Switch contact tab
« Reply #3 on: 15 Jan 2019 at 17:20 »
Thanks Andy 1303 and Red.
Sorry but that's not the info I need.
Stud number 9 should have a brass springy contact of some kind that bears against some  brass rings that wrap around the central shaft of the switch. That's what I am trying to replicate, but don't know what it looks like, or which of the brass rings it contacts.  I don't have one so can't describe it to you. But presumably it's similar but not identical to the ones on the other  terminals.
It's what I need to make, but don't have one to copy. And I don't know how many of the brass rings it should contact.
But thanks any-way.
« Last Edit: 15 Jan 2019 at 17:31 by BrmBrm »

Offline Roys rider

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Re: Douglas Dragonfly make a Switch contact tab
« Reply #4 on: 18 Jan 2019 at 21:32 »
Hope these help. If this is not what you want let me know. There should be 3 photos of a brand new switch. Apologies it is not easy to focus on the right bit. ( has the nut on it.
I made a mistake and used locking connectors which are great as they wont fall off but are a pig to get off so I would prefer not to have to take them off but will if that will help.
Peter

Offline Roys rider

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Re: Douglas Dragonfly make a Switch contact tab
« Reply #5 on: 18 Jan 2019 at 21:48 »
and 2 more photos.

Offline BrmBrm

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Re: Douglas Dragonfly make a Switch contact tab
« Reply #6 on: 19 Jan 2019 at 12:14 »
The photos are suberb, RoysRider.
That's exactly the tab I have to repliicate,
(and tighten an existing terminal tab on terminal 5).

Please don't dismantle anything more, in case something goes wrong!
Bye the way, yours is a new switch - where did you get it from - are they still available.
Many thanks,
Dave

Offline Roys rider

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Re: Douglas Dragonfly make a Switch contact tab
« Reply #7 on: 19 Jan 2019 at 16:05 »
It was left to me (with another d/f) by my father who bought it in 1974 from club spares - not sure if they have any left. ;-)
Peter

 

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