I bought a Pinball Life classic stern rebuild kit, with 2 classic stern flipper bats (version 1). The Flipper shaft barely fit into the pawl on the rebuild kit on one of the flippers, the other flipper I had to hammer the actual bat in (without any set screws installed). At first I thought this was nice because it makes it a lot easier to adjust the angle of the flippers, however the 2nd flipper now is binding (won't return to rest). I wanted to see if I could grind down the shaft a bit, but now I can't even get the flipper shaft out! I have placed a philipps screwdriver underneath the playfield, through the pawl, hammering it to push it through the top of the playfield, and got it part way out, but it's hung up on something. Once again, this is with no set screws installed. The bottom part of the shaft, is too big to fit through the pawl.

Were these the correct parts to fit with each other?

Classic Stern Shoe and Shaft Flipper Bat Assembly - 02/77- 03/1980 (Type 1) SKU: 1A-284_C-611-5
("https://www.pinballlife.com/classic-stern-shoe-and-shaft-flipper-bat-assembly-1977-1980.html")

Classic Stern Flipper Rebuild Kit - 02/1977-11/1981 SKU: stn_flip_rebuild
("https://www.pinballlife.com/classic-stern-flipper-rebuild-kit-left-and-right-flippers.html")

-Pat

I don't even know how to make it perfectly round if I was to reduce the diameter of the shaft at the bottom. I don't have a metal laithe, or a sanding belt (I wouldn't make it perfect with that anyways.)

It is going through the bushing ok. I think the reason it's binding is possible the pawl (crank) is just a little out of whack being pushed down too far. I'm going to research some options with just putting it back in. Maybe there is someway to ensure the pawl (crank) is close enough to the baseplate as it should be, then mallet the bat from the top of the playfield to put it back in. I wonder if some sort of lubricant would have an effect also, without being too messy.

I'm also going to have my wife help me remove it (holding the playfield still) and give it a real good whack or two. If that doesn't remove it, I'm scared to violently hammer it anymore. Guess I could use heat, but that is concerning too LOL.

So the problem I have now I guess is removing it to place another in there. Terry/Margaret have always been good taking care of problems, I just don't know how to remove it safely now.

-Pat

I'm wondering if the cause for the binding was the flipper shaft wasn't as far down as it could go in the pawl because it was so tight, therefore causing the pawl to be a little crooked. If I can't get it out, maybe I can hammer it in from the top, while holding the pawl up against the baseplate to try to get the shaft all the way through.

It's so tight, it's a little ridiculous. I'd rather get it out, get the proper shaft, and use the set screws to tighten instead of hammering everything. Especially since this is a game I'm probably selling soon.

Terry responded and is going to replace. TY Terry!

-Pat

Edit: Cutting the shaft is an option, however I would need to replace a brand new pawl, or entire linkage.
Also just an FYI. I've been restoring games for 35 years, so have rebuilt about 100 pairs of flippers or so. I've never even seen anything anywhere close to how tight this is.

Got the shaft out with my wife's help, lol. She held the playfield tight, and the pawl up against the plate, while I got in position and gave it a good 2 whacks with the mallet. Shot it over the head lol. And no damage to anything. Thanks guys, it was a weird one indeed.

Hey, 3 people picked up on that. I noticed that comment sounded NC-17 after I posted, but thought I'd leave it for laughs.