My $2.20 ignition tool.
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Joined: Dec 2006
Posts: 6,724
Likes: 234
From: Altoona, Pa.
My $2.20 ignition tool.
After watching the video we've seen here of the removal of the touring ignition switch, I deceided to make the copper tool that the guy had made. Got a piece of soft copper and tried to make one but the diameter of it was a bit too big. So studied and measured the stem of the ignition switch and felt one could be made from a common bolt.
Bought a 7/16" x 5" bolt and cut the head off of it. Took my angle grinder and started grinding. Ground both sides of the bolt back about 2 1/2". kept grinding both sides of the bolt equally, trying it in the ignition hole until it finally slid down past the lugs deep in the hole.
For the lever piece, at Lowes I bought one of those U bolts that have a metal plate held on by the nuts. Took two nuts and threaded them on the threads of the bolt, sandwiching the metal plate between them. Put the tool into the ignition and lined up the metal piece pointing at the LOCK position. Works like a charm to move the switch to any position without messing up the lugs.
If ya dont have a angle grinder, hope over the Harbor Freight and they have one usually on sale for 10 bucks. I have several good ones but bought one of these just to see what 10 bucks would buy. See pics of tool below.
Bought a 7/16" x 5" bolt and cut the head off of it. Took my angle grinder and started grinding. Ground both sides of the bolt back about 2 1/2". kept grinding both sides of the bolt equally, trying it in the ignition hole until it finally slid down past the lugs deep in the hole.
For the lever piece, at Lowes I bought one of those U bolts that have a metal plate held on by the nuts. Took two nuts and threaded them on the threads of the bolt, sandwiching the metal plate between them. Put the tool into the ignition and lined up the metal piece pointing at the LOCK position. Works like a charm to move the switch to any position without messing up the lugs.
If ya dont have a angle grinder, hope over the Harbor Freight and they have one usually on sale for 10 bucks. I have several good ones but bought one of these just to see what 10 bucks would buy. See pics of tool below.
Elite HDF Member
Joined: Nov 2010
Posts: 3,846
Likes: 173
From: Simi Valley, CA
Yep that works.
I made one similar to yours except I started with a smaller diameter bolt and forged it into shape. Then a nylon bushing, a fender washer, a couple nuts, and a small plastic t-handle screwed onto the threaded end to finish it off.
Your method of fabricating the tool is much simpler than mine. Working in the aerospace industry, I sometimes have a tendency to over-engineer things LOL.
I made one similar to yours except I started with a smaller diameter bolt and forged it into shape. Then a nylon bushing, a fender washer, a couple nuts, and a small plastic t-handle screwed onto the threaded end to finish it off.
Your method of fabricating the tool is much simpler than mine. Working in the aerospace industry, I sometimes have a tendency to over-engineer things LOL.
Last edited by 2black1s; Sep 23, 2012 at 06:15 PM.
Club Member
Joined: Jun 2009
Posts: 5,323
Likes: 37
From: NJ
Yep that works.
I made one similar to yours except I started with a smaller diameter bolt and forged it into shape. Then a nylon bushing, a fender washer, a couple nuts, and a small plastic t-handle screwed onto the threaded end to finish it off.
Your method of fabricating the tool is much simpler than mine. Working in the aerospace industry, I sometimes have a tendency to over-engineer things LOL.
I made one similar to yours except I started with a smaller diameter bolt and forged it into shape. Then a nylon bushing, a fender washer, a couple nuts, and a small plastic t-handle screwed onto the threaded end to finish it off.
Your method of fabricating the tool is much simpler than mine. Working in the aerospace industry, I sometimes have a tendency to over-engineer things LOL.
Seasoned HDF Member
Joined: Jun 2006
Posts: 28,552
Likes: 3,954
From: Vermont
Heck, for $25 you can get an actual machined tool http://www.marcparnes.com/HarleyIgnitionSwitchTool.htm from Marc Parnes
Thread Starter
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Supporter
Joined: Dec 2006
Posts: 6,724
Likes: 234
From: Altoona, Pa.
Yep that works.
I made one similar to yours except I started with a smaller diameter bolt and forged it into shape. Then a nylon bushing, a fender washer, a couple nuts, and a small plastic t-handle screwed onto the threaded end to finish it off.
Your method of fabricating the tool is much simpler than mine. Working in the aerospace industry, I sometimes have a tendency to over-engineer things LOL.
I made one similar to yours except I started with a smaller diameter bolt and forged it into shape. Then a nylon bushing, a fender washer, a couple nuts, and a small plastic t-handle screwed onto the threaded end to finish it off.
Your method of fabricating the tool is much simpler than mine. Working in the aerospace industry, I sometimes have a tendency to over-engineer things LOL.
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Tourer
Joined: May 2012
Posts: 367
Likes: 0
From: MI
You guys didn't make that...the government did
Seriously though, I love going through these threads and seeing how ingenuity kicks in when necessity dictates.
Seriously though, I love going through these threads and seeing how ingenuity kicks in when necessity dictates.
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Outstanding HDF Member
Joined: Jun 2010
Posts: 2,015
Likes: 3
From: Moline, IL
i see all these tools but i never needed one for mine. i had planned on making one similar to the OP, but ive had mine apart few times and no tool needed, i wonder if im doing somwthing wrong lol