Some progress has been made but unfortunately even though I did a lot of work nothing is in the "done" column and most of it was backtracking...sigh
As posted earlier, the section going into the helicopter ball lift must have had some heavy heavy usage as both the curved outer wall and the straight inner wall have broken supports.IMG_4024 (resized).jpg
Fortunately the metal itself is ok, its just the supports riveted on that are broken. With PBR unable to supply a replacement I set about to make my own.
The angle braces were relatively easy to create, I picked up a small piece of .025 sheet metal and I cut off a couple of pieces about the right size and ground them down until they seemed about right, then it was a simple matter of drilling new holes and I had a set of replacements. They were kind of scratched up so I threw them into the tumbler to see if they would clean up, while I looked at the other brace. IMG_4049 (resized).jpgIMG_4053 (resized).jpgIMG_4054 (resized).jpg
The other one was trickier as it had a threaded base and a flat spot where it was riveted. My first thought was to take a long bolt, cut off the top and then grind the end flat.IMG_4052 (resized).jpg
I actually did it then realized that the bolt was not thick enough to have the proper sized hole. At the hardware store, I purchased a couple of wingpbolts. They have a threaded end and a large flat area for your fingers. I ground down the flat area until it wasn't too wide and drilled a hole in it. Then it was a simple matter of riveting it onto the piece amd it was done!IMG_4055 (resized).jpgIMG_4056 (resized).jpg
Its not quite as shiny but I don't think anyone will notice. The bolt is slightly larger but that goes into the table and cannot be noticed either. So I placed it in the table and it worked beautifully.
I did notice my rivets are slightly larger than the original ones and that got me thinking that perhaps that even though it is below where the ball touches the wall, the ball might touch the rivet. It was a quick and easy check.IMG_4058 (resized).jpg
And sure enough, the ball hits the rivet.. that is not going to work. So I have a new set of rivets on order and I am going to have to drill out the one I already did...sigh