Beogram 4002 (5503): Repair of a Cracked Solenoid Lever

I recently received a request from a customer to help with a cracked solenoid lever from a Beogram 4002 Type 5503. The AC versions of the 4002 use a mechanical switch to limit the solenoid current after it has been activated during the arm lowering process. This means that the solenoid arm is elongated with a tab that presses the switch down after the arm is lowered. In some later AC motor versions this extension is achieved by a plastic extension that is riveted to the solenoid lever.

I checked my photo album of earlier AC motor Beogram restorations, and I found several instances where this plastic lever extension was glued back together with epoxy. Here is an example (check the area under the solenoid wires, and the yellowish blob of epoxy is apparent):

Earlier AC-motor versions use an all-metal lever:

I guess the 'streamlining' of the manufacturing process went in the wrong direction with this plastic feature...;-)

It is important that this lever does its job, since without pulling the switch down, the solenoid will overheat after a few minutes and can get permanently damaged.

Anyway, this is the cracked part I received in the mail:

The crack is basically a stress fracture due to the rivet hole in the plastic. I carefully drilled the rived out

And designed an 'improved design' 3D printed replacement part. I made sure the part was fortified around the small bolt I used to fix it to the metal lever:

This shows the part installed in one of my Beogram 4002s. First in the 'arm up' position

and then in the 'arm down' position:

Beolovely! Let's see how long this plastic part will last! Time to send it back to the Beogram it came from and find out!..;-). Life is a learning curve!