How To: Recreate the horn assembly on Cisco Heat

OSGamer

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I figured I would post this up, in case anyone else buys a machine missing a horn assembly. I was unable to find one, so I made one. I started by buying a big button from eBay:

The fit was perfect, but the microswitch assembly would not fit in the space provided:

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The original setup had a bar that went through the steering column, and actuated a microswitch at the rear of the column. So I ran to the hardware store, and bought a dowel rod, nylon washer, and a spring. I stuck the dowel into the column shaft until it was just touching the microswitch. Then I cut the rod at the column opening. I then measured the amount that the button stuck out from the back of the steering wheel, and cut that amount off the rod. I assembled the rod, washer, and spring like this:

27972784074_large.jpg


Test fitting, I realized that the original spring was too big, so I cut it down before taking the pic. After that, I did another test fit:

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and here it is all together:

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It works GREAT! Best of all, I spent $4.50 shipped on the button, and $3.27 for the parts at the hardware store. So for less than $10, I was able to bring my system up to 100% functional.

The spring that I used is still a little stiff, so I may swap it out for a weaker one down the road. But for now, I am very happy with the results. Hope this helps anyone that may have a similar issue.
 
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