Quoted from Lovef2k:
Ok, you scared me for a minute, I thought you might be cleaning out the holes in the PF to make them fit. Installing new inserts is a challenge, especially when they have a die letter stamped on the top of them. Do you have a Dremel with a drum sander attachment? I think this would less effort than using a hand file. If you don't have a Dremel yet, it's a "must have" for doing pin work like this. In my experience, it's impossible to get a new insert to sit flush with the PF surface and need to sand the tops down until flush. As I told you earlier, a variable speed sander at low speed works the best. Don't let the inserts get hot from sanding as this will cause the to bubble or raise in the center.
How is the blue color of these new inserts? I see from your earlier pics that you got the same part numbers that Marco just gave me for the new batch. Are the 3/4 and 1 inch insert colors consistent?
I did use the round file a bit to clean up some of the holes on the PF that were fighting me but I'm NOT cutting into the shoulder that should keep the inserts from falling through. I started off GENTLY filing the tops of the new inserts with the flat file but switched to 220 grit sandpaper because it just works..better. I'm still using the flat file to cut the bottom side of the inserts enough for them to not require a TON of additional sanding topside to be flush against the playfield.
I generally sand the sides a bit as well, if not to help them fit a bit less tightly, then to give them some tack for adhesive to grab on to.
I'm willing to admit that I may have no idea what the hell I'm doing I do have a dremel and it got away from me when I was cleaning up the insert that I broke out (and left the edges still glued in)... so I'm trying to avoid touching it again lol
The 3/4 and 1" inserts do match. Imo it's more of a "light blue" than the original dark blue but I think they'll look okay. Sure beats cracked and/or glue-covered crap like I had.
Temps are supposed to be in the 60s all week. I'm hoping to have this ready to clear in the next couple of days. Earplugs arrived today and I think those will work just fine crammed into the sockets. I'm ready to get moving on this damn thing.