Hi Zeke,
The stop solenoid on my Ford Lehman became intermittent last year and your
(awe inspiring) hand actuation trick worked until I found time to operate.
Investigation finally revealed too large a voltage drop through the coil
alone. Out of curiosity, expecting a corroded wire, I started unwinding the
coil. The wire looked fine until the last inch where it is simply stuck
into a small hole drilled into the iron core (armature) of the solenoid. I
cut a half-inch off the end of the wire and scraped the varnish from an
additional half-inch. After cleaning the small hole I flattened the end of
the wire slightly with hammer blows so that it would conform to the side of
the hole. Once the wire end was inserted I wedged it against the side of the
hole by driving in a round pin. I filled the remaining space with varnish.
I had wrapped the wire on a large coffee can as I unwound it from the coil.
To rewind, I found I could mount the rotary axis of the armature on the
spindle of a discarded electric can opener, which I rigged with a foot
switch. Some careful level winding by hand finished the job. It has worked
fine since.
Bottom line: if you are not a mechanic/machinist, buy a new one.
Jerry O'Neill
GB32 Adventure
Annapolis, MD