Ignition Switch Lug

[bendyminge]

Evening gang, hoping someone can give me some ideas on how to resolve this....
Having had my stuff back from paint, I'm starting to reassemble and have just put on one of the only things I didn't dry fit before paint, the MB ignition switch. The problem is that the lug on the headset that stops the switch spinning seems to have worn away so much that it wouldn't do just that, stop it spinning.
I could screw the cap on nice and tight, but I know that'd soon work itself loose after constant key turns, and after spending £1000+ on paint, I'm loathe to do any sort of welding or build up work.
Does anyone have any ideas that won't hurt my paint job?!

Ben

[Warkton Tornado No.1]

Make a special ‘anti-rotation plate’

Essentially, some thin sheet metal that has an external profile that fits the inside of your headset such that it won’t rotate.

Then, the hard part(!) make a hole to fit your ignition switch that has a little lug in line with the slot in the switch. It will look a bit like a gaping b#tthole with a haemorrhoid hanging down.

(It’s probably true to say that most scooterists that have suffered soaked knacker-carriages & dried themselves of against radiators & suffered the dreaded plukes as the result)

If it fits your switch though, it will stop it rotating & the nut will stay tight.

[bendyminge]

Thanks Warkton, I'll give that a go....not sure why I didn't think of that one myself!

Ben