Quoted from chickenscratch:Side question, would anyone have or snap a pick of washer/spring order on rod. Is there a washer on outer cushion spring as well as one on each side of main power spring?
There's no need to add additional washers. Pinball Life has a good assembly picture showing where the two flat washers should go:
Stern ball shooter assembly picture from Pinball Life
There is also the e-clip just behind the plunger tip rubber that retains the inner spring and sort of acts like a washer.
Quoted from chickenscratch:Going to try a single washer under fork instead of double, stronger/weaker auto plunge, etc. one at a time, maybe a stronger spring or extra washer on main spring to get it into a tighter coil (not sure that’s how it works but sounds reasonable) and then move onto a Stern ticket as I’m running out of options.
Some general tips in case you haven't tried them yet:
JP seems to be really picky about level. Use a level with a digital readout and make sure the table is level side to side, measuring off the playfield and not the cabinet or glass. Ignore the bubble level on the playfield and measure the playfield pitch near the flippers and closer to the truck assembly. You'll likely get different readings, you can average them or lean more toward the flipper area pitch, your call. Keith Elwin recommended a seven degree pitch, I prefer a six and a half to make the ball exits out of the pop area gate near the truck a little easier to save.
For the shooting lane ramp, do you have a slow motion video record option on your phone? A slow motion video of a ball launch will show if the ramp forks need adjusting. The premise behind using the washers is that the routed cutout for the ramp is too deep on the left fork on some (Maybe all) playfields, so the ball doesn't travel up the middle of the launch ramp and drifts left. This misalignment makes manual plunges and auto-launches of the ball hit the Helicopter half-pipe off-center and reject, or brick entirely in extreme cases. Lifting the left fork with washers makes sure the ball travels up the ramp channel each time, although it shouldn't be raised so high the ball catches the front edge of the fork.
As for the plunger inner spring, the green spring that ships with tables will be generally too weak to make launches up the half-pipe unless you rip the plunger, orange is ideal (And reportedly what should be included), and blue works but a bit too strong and hits the half-pipe pretty hard with longer pulls. Other than the spring strength or the shooter rod not moving smoothly through the shaft, the other big item is checking the plunger rod tip is vertically and horizontally aligned with the center of the ball in the plunger lane. That might mean removing the assembly and cutting out bigger openings for the plate screw shafts if it's really bad. I'd strongly recommend trying an orange spring to see if it resolves manual plunger issues before carving on the cabinet, though.
For the auto plunger, the ball should make even contact with both forks on the auto-plunger kicker arm. Another assembly picture from Marco Specialties in the lower left shows the rounded forks I'm talking about that sit behind and strike the ball:
Auto-plunger assembly picture from Marco Specialties
If only one fork touches the ball, or the ball has to shift sideways in the lane to rest on both forks when you pull the plunger rod back, bend one or both forks with a pair of pliers as needed. Ideally, the ball should only move forward or backward in the lane switching between resting on the shooter rod tip and kicker arm forks. It might be worth a try to bend the tips of the forks a little closer together to contact more toward the center of the pinball (Maybe 5/8"-3/4" apart?) making sure the forks can't clip the shooter rod assembly.
If aligning or adjusting the forks doesn't fix the auto-plunge issue, try dropping the auto-plunger power value by five or ten from default and see what happens. It seems counter-intuitive to lower the strength to start, but if the plunge strength is too hard, the ball can bounce off the back of the half-pipe more that it will roll up the half pipe. If the auto-plunges are rolling partway up the half-pipe and back down or rolling up the half-pipe and dropping straight down before getting to the rail, then you can start incrementing the plunger power by fives until you find a value that consistently makes it up the half-pipe.