I had a little project that kept me busy for a couple days. A fellow sewing enthusiast was lamenting a broken lever on her Elna Supermatic and I realized it was exactly the same failure that the same lever on one of my (three) Supermatics has. So I thought it would be a good challenge to see if I could come up with a replacement for her and I’d be able to use my machine as the Guinea pig.
This is what’s left of my original lever. As you can see it’s pretty small and understandably fragile so small wonder they break. Plus there’s a sliding feature as well which further reduces the available metal. I’m not sure why the sliding feature is there, really, as it doesn’t seem to get mentioned in any manuals I’ve seen so I decided to steer away from that and just make a non-sliding replacement.
Operation of the lever is pretty basic: it just swings back and forth and engages in one of five detent notches on the chassis trim. This is an illustration from one of my manuals — the lever is identified as part 3.
My plan was to make a copy of my broken lever but modify the arm portion into an inverted v-shape to engage the detents. Rather than try to whittle this all from thicker stock I decided I would press the “v” into my shape. The chosen metal would be a scrap of salvaged pallet banding which is the closest thing to spring steel that I have kicking around in the right thickness (0.020”). It’s a little hard but with decent tools it drills and shapes easily enough. I cut the shape using my jewellers saw using a photocopied template of the original.
Usually by the time I get to this point I start getting impatient and start thinking how to makes things go fast! The bottom part of my press die would be a block of aluminum with a little v-groove cut in on the shaper. The top part would be a triangular-shaped bit of steel that was hiding inside a broken drill bit….
Now how to hold everything in alignment and in the correct position while I pressed it? Need something…..squishy…..like plasticine! So I taped the blank to the block over the v-groove, put three little dabs of plasticine over the blank, pressed my triangle into the clay, and then squished it….
Worked great! The plasticine held everything in position until the press came into contact and then squished out of the way as pressure was applied.
And the rest was gravy, as they say. I finished cleaning up the blank, tweaked the springiness a little to solidly engage the detents, and fashioned a knob from some black acetal I had in stock. I think it’ll be okay for the intended use and it’ll be on its way to Portland as soon as I can get it into the mail.
Thanks for looking!
-frank