Catalina 30 TRBS #2889 "Northern Light"

The "D" shaped shaft hole in the original black lever was 5/32" diameter. Over time the hole had been worn round. I drilled through the lever and shaft and fitted a dowel pin. That worked for awhile, but any dowel pin (or spring pin or cotter pin) had to be fairly thin to fit through the 5/32" shaft, and it periodically sheared.

A new lever was fabricated out of aluminum that is longer than the old lever.

Because "D" shaped drill bits are difficult to find, and because I didn't have a "D" shaped broach, I created the "D" shaped hole as follows:

• a 0.159" diameter hole was drilled in an aluminum bar
• the bar width was reduced by milling to create the "D" shape
• a small block was fabricated to create the flat side of the "D"
• the blocks is held in place by two 6-32 screws