Apologies if this has been done before, but I thought I would post my attempt at a solution for the deaded failing power switch in an SX-450. I decided to try mounting a snap action lever switch in the existing plastic switch housing where the cam could actuate it. I found a small switch rated at 10A/250 VAC that had the right dimensions at Mouser - https://www.mouser.com/ProductDetail/642-MBF5B2
I was going try to 3D print something, but my CAD skills are rusty. I'm sure it would have taken me longer just to design some kind of mounting plate than mod the existing switch. I had to trim the inner wall of the plastic housing to allow the switch to stick out the top. I started with a wood chisel, but broke out the Dremel - partly to reduce the chance of slicing a finger off. Slow speeds made quick work of it without melting the plastic. I followed up with a file to smooth it down a bit. It's still rough, but close enough. Because nothing is ever as simple as you envision, the switch mounting holes needed to be just above the housing. I cut & drilled a scrap of aluminum to support it. It seems to be lined up correctly after adding washers as spacers - and it clears the dial string! It's getting late, so I'll cut the screws down and solder it up tomorrow night and hopefully this works as a permanent fix.
I was going try to 3D print something, but my CAD skills are rusty. I'm sure it would have taken me longer just to design some kind of mounting plate than mod the existing switch. I had to trim the inner wall of the plastic housing to allow the switch to stick out the top. I started with a wood chisel, but broke out the Dremel - partly to reduce the chance of slicing a finger off. Slow speeds made quick work of it without melting the plastic. I followed up with a file to smooth it down a bit. It's still rough, but close enough. Because nothing is ever as simple as you envision, the switch mounting holes needed to be just above the housing. I cut & drilled a scrap of aluminum to support it. It seems to be lined up correctly after adding washers as spacers - and it clears the dial string! It's getting late, so I'll cut the screws down and solder it up tomorrow night and hopefully this works as a permanent fix.
