Repairing broken metal pegs on badges - UK Vintage Radio Repair and Restoration Discussion Forum

Mike Phelan · 29th Mar 2006, 7:29 pm

Hello fellow avocados.
I have just managed to successfully repair one of those very fragile metal pins on a Hacker badge - the sort made of metal, possibly copper and then plated. So, I thought this may be of use.

The problem is that the original seems to be resistance welded, and any sort of drilling would show on the outside surface, unless it is a very small hole. (Pic 1)

Tools needed - small file, 0.6mm spade drill (you could make one of these from a needle) pin vice, brass tapered clock pin and brass bushing wire, or similar brass tube - O/D like original pin, bore about 0.5-0.6mm.

Yes, I know you probably do not have a supply of clock materials as I have, but the pins and bushing wire from www.m-p.co.uk are very cheap, as are pic vices from all sorts of places.

Carefully drill the badge where the pin was - do not do it under power!

Choose a brass clock pin that goes almost all the way in and is longer than the broken pin.

Take it out, put it in the pin vice leaving the thick end protruding about 2mm, and peen it over with a small hammer to make a sort of rivet.

Drive this into the hole on the badge so the thin end protrudes at the back. (Pic 2)

Cut a length of bushing wire - roll it with a Stanley knife or similar.

Tidy the end up with a file and push it over the pin. Ideally the pin should project by 2mm or so.

Solder this end to the bushing wire (Pic 3) - et voila! You could touch up the tiny pin head on the outside if necessary.

Nickthedentist · 29th Mar 2006, 7:49 pm

Amazing, Mike

I would have bodged it with Araldite

Thanks for yet another useful tip.

Nick.

Mike Phelan · 30th Mar 2006, 8:33 am

I would have done the same, Nick, but there is no room to do it!
Damn - just spotted a typo on the subject line and cannot do owt about it.

Paul Stenning · 30th Mar 2006, 5:52 pm

Quote:

Originally Posted by Mike Phelan

Damn - just spotted a typo on the subject line and cannot do owt about it.

I can - so I have!

Mike Phelan · 30th Mar 2006, 6:17 pm

Thanks, Paul!

29th Mar 2006, 7:29 pm	#1
Mike Phelan Dekatron Join Date: Nov 2003 Location: Near Leeds, West Yorkshire, UK Posts: 4,609	Repairing broken metal pegs on badges Hello fellow avocados. I have just managed to successfully repair one of those very fragile metal pins on a Hacker badge - the sort made of metal, possibly copper and then plated. So, I thought this may be of use. The problem is that the original seems to be resistance welded, and any sort of drilling would show on the outside surface, unless it is a very small hole. (Pic 1) Tools needed - small file, 0.6mm spade drill (you could make one of these from a needle) pin vice, brass tapered clock pin and brass bushing wire, or similar brass tube - O/D like original pin, bore about 0.5-0.6mm. Yes, I know you probably do not have a supply of clock materials as I have, but the pins and bushing wire from www.m-p.co.uk are very cheap, as are pic vices from all sorts of places. Carefully drill the badge where the pin was - do not do it under power! Choose a brass clock pin that goes almost all the way in and is longer than the broken pin. Take it out, put it in the pin vice leaving the thick end protruding about 2mm, and peen it over with a small hammer to make a sort of rivet. Drive this into the hole on the badge so the thin end protrudes at the back. (Pic 2) Cut a length of bushing wire - roll it with a Stanley knife or similar. Tidy the end up with a file and push it over the pin. Ideally the pin should project by 2mm or so. Solder this end to the bushing wire (Pic 3) - et voila! You could touch up the tiny pin head on the outside if necessary. Attached Thumbnails __________________ Mike.

29th Mar 2006, 7:49 pm	#2
Nickthedentist Dekatron Join Date: Jan 2005 Location: Oxford, UK. Posts: 17,846	Re: Repairing broken metal pegs on badges Amazing, Mike I would have bodged it with Araldite Thanks for yet another useful tip. Nick. Last edited by Paul Stenning; 30th Mar 2006 at 5:52 pm.

30th Mar 2006, 8:33 am	#3
Mike Phelan Dekatron Join Date: Nov 2003 Location: Near Leeds, West Yorkshire, UK Posts: 4,609	Re: Repairing broken metal pegs on badges I would have done the same, Nick, but there is no room to do it! Damn - just spotted a typo on the subject line and cannot do owt about it. __________________ Mike.

30th Mar 2006, 6:17 pm	#5
Mike Phelan Dekatron Join Date: Nov 2003 Location: Near Leeds, West Yorkshire, UK Posts: 4,609	Re: Repairing broken metal pegs on badges Thanks, Paul! __________________ Mike.