I posted thi s a few years ago but here it is again in case it's any help to
anyone.
FWIW my horn works as well as ever.
"I put up with this problem for a few years but after adopting the following
rather inelegant solution about 20 years ago the horns have worked perfectly
ever since.
First I made a new plunger thingy. Took the carbon rod from a dry battery
which fitted well into the barrel of an old pen of correct diameter. Took a
very light compression spring, same one from the old ballpoint, I think. Cut
two pieces 10 mm or so from the carbon rod and glued them to the spring.
They fitted into a piece of the ballpoint barrel cut to the appropriate
length.
Voila! A new plunger thingy.
Next I ground the teeth off an old hacksaw blade and bolted a suitable
length of it to the master cylinders bracket so that the flat bore down on
the upper part of the steering column.
Encore Voila! A perfect earth. No need to fiddle with bits of wire over the
UJ's or steering rack."
HTH, ATB
David Brister
1967 TR4A
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