Interesting analysis Glen, bu I think you missed the real problem...
... you'll notice right after you painted yours in...
Bright yellow paint!
After all, Frank has the most problem with them...'-)
Gerard
At 3:08 PM -0800 1/4/02, Glen Byrns wrote:
>So why do the modern day replacement brakelight switches fail?
>(fluid pressure activated type, like in the bugeye)
>
>Mine went after two years, so after putting in a replacement from
>"Interpart" of England, I cut apart the old one and checked out its guts.
>
>The rubber diaphragm was intact and free of any leaks yet there was brake
>fluid on the 'dry' side of the diaphragm. This had caused a dark deposit to
>coat the contacts and the disc that is pressed to the contacts by the
>diaphragm when you step on the brake. With both parts of the switch covered
>in this dark film of 'stuff', there was NO current flow through the switch.
>The clamping surfaces of the switch were clean and free of any burrs or
>particles that might have created a leak.
>
>Near as I can tell, it appears that the crimping process that closes the
>body of the switch does not apply enough pre-load to compress the rubber
>diaphragm and completely seal the switch. In time brake fluid leaks around
>the rubber diaphragm and contaminates the contacts until they no longer
>conduct electricity.
>
>Speculation: Old switches used a different rubber formula that did not
>produce any 'black stuff' even when a bit of fluid got around the seal, so
>they worked even when contaminated. OR... the new ones are not crimped
>shut with enough force to ensure a fluid-proof seal.
>
>Regards,
>Glen Byrns
>'59 bugeye
>'59 Morris Traveller (Winifred)
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