[Rob Doe]

A year ago, I researched every issue stated above. Our coupe had the repro canisters and bale. The contact plate was overly thick. the wires were loose and spliced. The horn contact at the center of the plate was sticky and did not respond to the spring tension as it should. The spider is frail.

I looked at each moving part until I understood its functioning. (Took a while to get it all, embarrassing to say the least) and this included in what positions the brass contacts on the upper part were in when the switch was in each of the 4 positions ... cowl lights, off, dim, bright. I also had the attach positions of the wires memorized before it was all over.

I paid the 50 bucks for the U.S. made to Ford's drawing setup from the vendors. I had to order the bale for the quality setup. The repro bale could not be adjusted to work after much effort.

I ordered a new contact plate from Tyree Harris. It was .312 thick as it should be. .310 - .315. What a pleasure to do business with Tyree was.

As to the male tab / key on the bottom of the upper switch housing / canister that slides into the female slot, ... the opening of the slot was filed slightly to assure there was a good enough fit to hold things together. See Snyders instructions parts 1 and 2 for the switch.

I was frustrated too. Hang in there Synchro. I also used all the pool hall adjectives learned during a misspent youth. LOL