Horn System Restoration

[blubau]

My 1969 Patrol has a banjo steering wheel and although not correct for the 69 IMO looks better and conveys the Patrol attitude.

The horn wasn’t working so I checked for ground at the wire coming out of the steering column under the hood (while horn button pushed). No ground, so investigation into the cause. I removed the center of the steering wheel hoping to find a simple solution under the button. The cap comes off using a flat blade screw driver inserted into a slot in between the button surround and the wheel. Instead of finding the expected horn button under the cap it was empty. This was a good time to align the steering wheel so I removed the center nut and took it for a drive to get the wheel straight. Another job accomplished.
Now back to the horn. While the steering wheel was removed I remove paint from the washer below the wheel that makes the ground contact. I looked in the parts manual and there’s a photo of the parts needed to activate the horn. Simple and foolproof, if the parts are there! (See photo below). Since my parts were missing, and I knew what they looked like, I took some measurements recording the space between the holes in the steering wheel behind the horn cap. It was 1” and spaced as a square with holes at each corner. I used that dimension to determine the size of the metal retainer and then used AI to draw me a template. That’s one of the first times AI has been accurate as it usually gives convincing, but false answers to my queries. (See photo below of template)
I then took TIG welding rod and bent the parts and cut out a circular piece of metal for the retainer. I used the template to mark the holes and drilled them out. (Photo of resultant part below)
Then installed the part and trimmed the push rods to length to give the button some, but very short throw to activate the horn.
Now the horn works, but it’s weak. I can hear the solenoid and sometimes a squeak. I remove the horn and take it apart and then file the contacts. Clean up the minor rust inside and reassemble then adjust using the tone adjustment screw. Sound good and another job accomplished.

[RiverPatrol]

Great sleuthing and craftsmanship. Nice job!

[Esteban]

Congratulations! Very detailed and easy to follow your repair.