Shelley Jack top saddle

[classical glass]

Has anyone successfully removed the top saddle of a Shelley jack? If so how did you do it without destroying anything? I want to replace the L shaped saddle with a correct one which is swaged or crimped on.
Thanks...

[my427cobra]

Hi classical glass. When I did mine, if I remember correctly, I used an end mill (5/8") to mill out the swage on the "L" shaped saddle. The screw shaft top is square in shape.

No way that I know of to re-swage the correct "saddle" shaped top back onto the shaft, so I had it welded and weld filled the round hole in the "saddle" and ground it to a smooth finish. Invisible after painting.

Cheers
Greg

[classical glass]

Originally Posted by my427cobra

Hi classical glass. When I did mine, if I remember correctly, I used an end mill (5/8") to mill out the swage on the "L" shaped saddle. The screw shaft top is square in shape.

No way that I know of to re-swage the correct "saddle" shaped top back onto the shaft, so I had it welded and weld filled the round hole in the "saddle" and ground it to a smooth finish. Invisible after painting.

Cheers
Greg

Thanks Greg, That's exactly what I'm going to do.

[Armrer]

I took a die grinder with a cut off wheel and slotted opposing sides of the saddle. I then flexed the saddle until it broke off cleanly. I cleaned the ‘mushroom’ off the shaft until the new saddle fit. Re-stake or weld to trap the new saddle.

[Armrer]

check ‘Tool Kit - Redux’ , page 4 in Originality Forum. On pages 7-9 of the thread, there’s a nice pix series of resto process of the Shelley jack-

[picah]

Originally Posted by Armrer

I took a die grinder with a cut off wheel and slotted opposing sides of the saddle. I then flexed the saddle until it broke off cleanly. I cleaned the ‘mushroom’ off the shaft until the new saddle fit. Re-stake or weld to trap the new saddle.

I did the same general procedure. Worked well. I would think that if you choose to weld, it is important that the curved saddle not be actually welded to the vertical shaft as it appears a bit of saddle free movement is important to allow the saddle to move as it contacts the 4" frame tube to maximize contact area and allow for slight misalignment. Just a thought.
Best
Ron

[Armrer]

Originally Posted by picah

I did the same general procedure. Worked well. I would think that if you choose to weld, it is important that the curved saddle not be actually welded to the vertical shaft as it appears a bit of saddle free movement is important to allow the saddle to move as it contacts the 4" frame tube to maximize contact area and allow for slight misalignment. Just a thought.
Best
Ron

Yes, as shown in the above mentioned Tool Kit thread, a dished washer welds to the shaft. That traps the saddle and allows it to rotate freely.