Brief Description: Installing the Right Side Intercom PTT Switch
Removed the left side switch to install a two prong plug on the end. Completed the mounting of the terminal blades on the end of the wires. Installed the switch back into the throttle handle and routed the wire long the throttle linkage behind the instrument panel. Mounted the terminals into the plug case and tested the fitting to the radio harness.
Drilled a hold in the right throttle handle and enlarged it to 0.258 inches to fit the switch. Split the two wires apart for about 1 1/4 inches and removed a 1/4 inch length of insulation from each wire end. Instilled heat shrink tubing on each of the wires going to the switch. Soldered the double 20 gage wire to the terminals on the switch. Slid the heat shrink tubing down over each terminal on the switch and fixed them in place. Added another heat shrink tube over the wires and terminals at the switch. Slid a final larger heat shrink tube over the switch body and applied heat to fix it in place. Found that too much heat had been applied to the switch body which froze the button in place. This rendered the switch useless. It was removed and the installation was repeated with a new switch.
After the new switch was mounted to the wires as described above it was ready to be mounted into the throttle handle. The attempt to get the nut started on the switch became a big challenge. After more than six tries the wire terminals failed from the back of the switch rendering it useless.
A third attempt was made with a new switch and again failed due to excess heat on the switch which caused the button to fail. That ended the day.
