Documenting a Banzai Run playfield set swap for 80spit machine. He has a really nice playing machine and is having me swap the playfields he got from Mirco a few years back. They look really nice and will go along with their new plastic set. It’s in good shape and pretty clean. There’s a few issues we’re aware of but nothing major. A couple of brackets are wrong so he has correct ones we’ll be installing.

He’s giving me carte blanche on it. So we will replace anything broken or wear items. I will go with new targets and switches and try and add some subtle color changes here and there. The main ramp looks to be replaced and in good nick so will be reused. I love to use TaylorVA rails and would use them if he was doing them right now. The ones here are good so will get reused.

Gerry will be redoing his cabinet while these are getting swapped. It should be a really nice restoration when he’s finished.

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Here’s some of the parts that need to get removed from the ends to mount to rotisserie.

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Karolina was checking it out as she’s the quality control supervisor. She must’ve had a hard day sleeping as usual.

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Top side tear down pics 1:

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Top side tear down pics 2:

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Top side tear down pics 3:

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Top side tear down pics 4:

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Top side tear down pics 5 of 5:

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Here's the post heights. Detailed locations at this post: https://pinside.com/pinball/forum/topic/banzai-run-playfield-set-swap#post-6156808

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The top side is mostly cleared. Actually I ran out of time so this was a good stopping point. This is the second square drive screw I've found and there's been a few more I've spotted such as the ramp sign. Either some of you Canadians had this or someone worked for SMED? Wonder if anyone even heard of them.

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LOL, very cool! I was looking forward to digging into this. It won't go nearly as quick as some others. That's for sure!

Bottom side tear down part 1

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Bottom side tear down part 2

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Bottom side tear down part 3

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Bottom side tear down part 4 of 5

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Bottom side tear down part 5 of 5. All stripped down.

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T nut count is (4) 8-32 for top side (hinges) and (34) 6-32 on the bottom.

I use old tumbler bearings (one of many tumblers that died) with felt on and a large washer with a hex screw to run in T nuts. After a few playfields it’s time to trash the felt and screw for new ones.

In this case the 8-32’s barrels were a touch too large to fit so opened them up. I use kruzman clear kit drill gauge to measure the barrel and found I needed a 15/64” drill.

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Here’s one minor difference. There is three separate holes in the new one here to adjust. I’ll skip the t nut and go with a washer and nut.

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Light boards are dry after ultrasonic and get mounted. Holes for these look great.

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First batch of parts are ready. I try and organize the parts when they’re done to speed up assembly. I can see why the pros use new hardware. Taking all the time to pick thru and dig out the screw holes takes a lot of time. So progress is light today.

Hinge plates and trough wire form installed on the bottom. Original rails are cleaned and reinstalled.

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My process of prepping holes is the same. These were a bit too small so had to open them up slightly. I use Ron’s clear kit to prep any playfield

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Getting some parts ordered and I have for pop bumper body options Zitt that I really like. Not sure which yet or what color skirts either. I also have plain white and opaque white.

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I’ll be going with new bats of unknown colors yet but still throw parts that look good in ultrasonic. Sometimes they’re good for spares or projects that I give back to the owners. Here’s one that hit the trash.

I have all the wire management on. Yeah some will come off for the GI braid...

A few Comets going in before a make a list.

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Mechanism assemblies part 1. Gerry brought over the brackets needed so they’re all right now. You’ll see in the sling pics showing a good replacement and the wrong one. He also brought the knocker over so it can get cleaned up too.

I’m going to do the lower playfield first so that’s what you’re seeing now. When the lower is mostly populated or at least mostly ready, I’ll start on the upper.

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Mechs part 2. Both the lower flipper 11630’s coils are really tight pulling out the sleeve. And the crispy cookie wrappers that crumble shown it’s seen some heat in its life. Will see if he wants to get new or has some good used 11630’s.

Not many parts will stay with the flippers. They’ll get the new WPC style springs too.

The outlane kicker has some wear. Will clean it up as a spare but will get a new one.

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Good news from Cliffy ! He had some templates for the flipper frames and I was able to match them up for him. We were going to send them out to him but doesn’t look like we will need to.

He’s made improvements too hence some differences.

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Star posts going on. Experimenting with different colors of posts and Titan_Pinball ring colors. I’m liking the black post at flipper and white ring. Will likely go with black flipper bats at least the lowers.

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The back panel has a chip out so using some Quik Wood for the repair. Not that little blue pill kind but it is Valentine’s Day.

The new front hangers from Gerry look much better now and installed.

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I’m using a clear and black star post at the lower areas near the slings to complement the checkered pattern in the playfield. I originally just had plain red which was fine but this is looking better to me.

The top side metal is all cleaned and regrained. Thankfully all the holes on the Mirco have been perfect to this point.

Test fitted the sling plastics.

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While waiting for the rest of the lamp holders, I started to run some braid and staple in.

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The first order came today from Marco. New targets and a lot of metal parts. I got him all new trough metal as they never clean up really nice. New targets and sticking with the Pringle colors as they’re matched to inserts and look correct as they are.

Going with the more opaque pop bumper bodies as it will still give a lot more light snd will have the nice LED rings. I think the clear one here would be too much light.

Unfortunately, the shorted me one pop skirt and missed one of the spinner decal sets. No big deal as they always fix these rare issues and immediately responded. They’re going to put them in my next order which will be very soon.

They sent this cool new keychain they have.

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The rest of the bulb holders came today too so I finished stapling and soldering them all in. Some of the yellow GI cross-wires were transferred over as they were in great shape once cleaned.

This is the Unicatch upholstery long nose stapler I use. It took a little over a full sleeve of staples. It’s been flawless for the 5+ years I’ve owned it. I do keep it lubed at every use with Amsoil air tool oil.

Couple pics of top side with pop bumpers, new metal trough parts, and full overview as of today.

The new stand up targets are all installed and the holes all lined up. Even the new sling hardware was perfect. Very happy so far.
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Today was soldering in the six bank stand up target harness, reflowing the light boards, stapling/soldering in the one rear GI bulb holder, and assessing the needed and missing Titan rings and LED’s for both playfields.

LED’s in GI are Comet sunlight 2SMD’s. Other than red, green and blue, the inserts will be sunlight non ghosting.

I’m going to use the amber pop bumper caps as they’ll complement the plastic above it well. They have some color but fairly translucent to help light the plastic up.

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Lot of parts ordered today. We have Titan rings and Comet LED’s coming along with another Marco order and they’re sending the missing parts from plastic order. Starship Fantasy subway ramp for upper playfield showed up today.

I laid in the rest of the harnesses. Micro switches will all be replaced.

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Most micro switches have been replaced. While there, I replaced the old badly yellowed tubing for the trough diodes and shooter lane switch.

All the stand up targets are soldered and installed.

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All the playfield micro switches are installed. There’s 9 of them on the lower and two on the upper for subway. There’s 3 for the ramp for 14 total.

Some of the mechanism are installed. Waiting on some coil labels held up in the mail. The kicker has the wrong bracket so will try and locate one.

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Karolina is getting her laser eyes ready to supervise the upper playfield portion.

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New spoons are installed along with the coil labels. I have all the mechanisms installed but the shooter lane feeder. Need to order one piece that has a loose stud.

Also the kickback dimples were too far left as the armature was hitting the side rail. So far that was the only simple issue and that was only slightly.

Couple of pics of progress:

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The ramp is a recently replaced new one so I’m just dissembling for cleaning. The wrong Canadian square heads will be replaced. Nothing wrong with them but trying to stay with correct hardware.

The harnesses are being ultrasonic’d, new switches will be installed (to replaced these flattened ones), and tumbled hardware. Some Comet LED’s will finish off the flashers.

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The upper playfield flipper bats all have cracks. So placed order for lower playfield using all black and uppers all yellow (limited by small flipper on available in yellow).

Top side mechs/coils soldered in. Will be adding in a sunlight strip light at apron to light up below the flippers. I’ll add a socket when the order comes so it’s easy to remove if not wanted.

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Placed the plastics on but can’t finish as the Titans are delayed in the mail.

Comet order came so any orange, yellow, or clear insert got sunlight non ghosting. Color matched NG on the red, green and blues. Flashers are cool whites flat top with exception of 25,000 point flasher which got a flex cool white.

The bottom side is mostly complete and soldered in. Flipper bases are polished and waiting the new coils. All 6 flipper coils will be new. Most were way too tight so we decided to go new. More and more I think new coils, especially flippers, should go new when you’re going through this much trouble. I had one that wasn’t too bad getting the sleeve out but the new one wouldn’t go all the way in. TWSS

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Top playfield tear down top side. Part 1

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Top playfield tear down top side. Part 2

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You have some time. I have a few parts to order and waiting until I get the upper torn down to make a list. I can’t wrap up the lower as the rings are stuck somewhere in Texas since the 19th. Hopefully everyone down there is safe.

Will do a “Where’s Waldo” of a Golden monkey for you to find.

Upper tear down on the bottom side. Some more Canadian screws found on the subway. I’ll get the correct hardware when installing the new subway. Someone spent a lot of time strengthening the old subway. Not pretty but was fully functional.

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Upper tear down on the bottom side part 2.

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Upper tear down on the bottom side part 3.

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Spinners were ultrasonic’d, sanded, painted and now new decals.

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The upper playfield mechanisms. They’re all in good nick. Just needing cleaning, rebuilt and new wrappers.

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The ramp parts are cleaned and finished tumbling so the new switches were soldered in and adjusted after the ramp was assembled.

The new targets are installed. All but one red and one yellow aren’t installed. I missed one and the red is in the way of mounting on the rotisserie.

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Karolina is supervising the harness. She said I need to clean it.

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I started populating some lamp holders and the GI relay. New T nuts are installed. There are (3) 6-32 and (47) 8-32 (Includes 8 on topside) t nuts on the upper playfield.

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I made it too easy lol!

Here’s the LED pop rings. I am testing cool white, warm white, and pink in that order. Pink is if ally nice but in this case is way too pink. I personally like the warm white the best but cool white isn’t bad.

One day I’ll put these in my own machines.
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I’ve wrapped up the stapling/GI lamp braid, wire managers and the 4 through posts.

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The Titans came as a welcome surprise so was able to finish up plastics after putting them on.

Not sure what looks best as they all look good for the lower flippers. Tested black, white, red and gray.

The ramp is fitted and looks to work fine. I need to Mylar under the ramp entry/drop. I’ll tidy up the wiring better when it’s installed for the last time.
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Some more parts today including the ball shooter section and some lamp holders. And the Enhanced Cliffy frames we fitted look to be perfect. Not sure when he’ll have these for sale but I’ll ask!
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Here’s them installed:

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I added one of the tree plastics by the right spinner. They include several extra tree plastics. Hoping to find a few more spots for the spares.

GI tested and ramp fitted. Mylar at the left ramp drop, ball return and ramp flap.

The pop caps look yellow but they’re actually an orange/amber in person. I have a warm white here. I wired up the strip behind the flipper and both ball ejects. I changed them to clear so they can be lit differently. The center eject is a fast color changer with the GI. The left eject is wired to light red along with the red “Banzai Hill”. Wanted this to stand out when lit.

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Cliff confirmed the flipper frames are for sale and ready to go!

Missed six 8-32 T nuts on the top side of the upper playfield. This takes more attention and using Ron’s kit will help prevent chips. I use a sharpie but if you’re careful you could use a hand nut driver and let the t nut make slight indentations.

Then use one of the bits Ron includes and seal it.

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Some new and some good ultrasonic’d Star posts now installed with tumbled hardware. There’s a bunch!

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