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David G4EBT · 7th Feb 2023, 4:30 pm

A while ago I restored an Ekco AC77 on which the top caps were flimsy and offensive to the eye (well to my eyes anyway), so they had to go. I made some new ones from 1.5mm brass sheet which only took a few minutes.

I've attached a rough sketch, and pics of an original one and a replacement I made.

To form the clip I rolled the brass around the shank of a 9mm drill bit, then adjusted it for a good fit on the top cap, but not so tight that it risked pulling off the cap. Brass 'work hardens' with bending and the clips were quite springy. The little tubular solder terminal I bent around a 2.5mm drill bit shank, then bent it down at right angles.

Only needs a vice, pair of tinsnips, a file and a junior hacksaw.

Ebay is awash with sellers of brass sheet of all thicknesses.

Typically a 200mm square sheet of 1.5mm thick sheet will cost a fiver post paid.

Just google:

'Brass sheet various sizes, various thickness. Models making, jewellery making' or:

'Brass Sheet plate guillotine Offcuts - 0.3mm to 3.0mm - Multiple Sizes'

Hope that's of interest.

7th Feb 2023, 4:30 pm	#17
David G4EBT Dekatron Join Date: Feb 2003 Location: Cottingham, East Yorkshire, UK. Posts: 5,761	Re: Top cap shortage? A while ago I restored an Ekco AC77 on which the top caps were flimsy and offensive to the eye (well to my eyes anyway), so they had to go. I made some new ones from 1.5mm brass sheet which only took a few minutes. I've attached a rough sketch, and pics of an original one and a replacement I made. To form the clip I rolled the brass around the shank of a 9mm drill bit, then adjusted it for a good fit on the top cap, but not so tight that it risked pulling off the cap. Brass 'work hardens' with bending and the clips were quite springy. The little tubular solder terminal I bent around a 2.5mm drill bit shank, then bent it down at right angles. Only needs a vice, pair of tinsnips, a file and a junior hacksaw. Ebay is awash with sellers of brass sheet of all thicknesses. Typically a 200mm square sheet of 1.5mm thick sheet will cost a fiver post paid. Just google: 'Brass sheet various sizes, various thickness. Models making, jewellery making' or: 'Brass Sheet plate guillotine Offcuts - 0.3mm to 3.0mm - Multiple Sizes' Hope that's of interest. Attached Thumbnails __________________ David. BVWS Member. G-QRP Club member 1339. Last edited by David G4EBT; 7th Feb 2023 at 4:39 pm.