I picked up an O22 that was missing one of its outside (insulated) binding posts and thought this would be a quick repair. So I ordered a nickel reproduction 711-100 binding post (from Trainz , if that matters) and now realize that I’ll need to set the rivet end in the tight vertical quarters of the switch machine framing (less than 1”, see photos). Does anyone have any suggestions about how to set this rivet without some sort of special anvil or tool that Lionel’s assembly line must have used? Or is repurposing an appropriate length 4-36 screw and a couple of nuts in place of the 711-100 the only real alternative to making it functional (if not pretty)?
Parenthetically, a couple of observations:
- The KL-23 insulating washer is a unique part with an “embossed” face that is just slightly raised to mate with a very small amount of the hex hole in concert with the 711-101 bushing (which occupies most of the hole’s depth). It also appears to be a two-piece part, as the embossed face doesn’t seem to be made of the same phenolic material as the rest of the washer.
- KL-23 also appears to have been itself riveted together for some unclear reason. While it appears to be a two-piece sandwich, it doesn’t seem the rivet/eyelet is needed to hold the face to the rest of the washer. It almost seems like it might be based upon something like a 61-22 lamp base to which the embossed face was, perhaps, glued?
- The replacement 711-100 binding post seems to be a more stout part than the original. Its rivet is too wide to pass through the KL-23’s rivet, which the original must have done. It also seems, to my eyes, that the rivet wall thickness is greater than what the other 711-100 in the switch seems to have peened over.
- NOS KL-23s seem to now be in short supply, although I think I can reuse the existing one. Perhaps sanding down a pair of the bushings to “meet in the middle” of the hex hole could be an alternative.
