Zaccaria Gen2 Flipper Rebuild

[Rob zombie]

Ok, I'm finally getting around to attempting the lower flipper rebuild on my Champ 82. Having to bastardise an older Bally rebuild kit coupled with the correct Zaccaria coils as you just cannot get these parts anywhere. First hurdle is that the Bally coil stops which appeared to fit actually have a narrower gap between the screw holes so I can't use them. Fortunately whatever coil stops were on there have a lot of meat still on them underneath all the grease and grime, so I will re-use those.

The next problem is that I want to seperate the flipper arm from plastic bit and switch those over. How do I go about seperating these without damaging anything? Does the holding pin just squeeze together and pop out? Or does it punch out? Or screw out?

 

[Rob zombie]

Or does the original arm look ok to re-use?

 

[DanLewell]

You need a punch to get the pin out. Something like these:
https://www.amazon.co.uk/Magiin-Storage-Removal-Automotive-Jewelry/dp/B07QQWYGF5

not sure if these will be the right size, just giving you an idea of what they look like.

Line it up and whack it hard with a heavy hammer. You want to use as few hits as possible to avoid damaging the pin if you want to reuse it.

You really need the punch to be the right size so it can push it all the way through.

 

[Rob zombie]

You need a punch to get the pin out. Something like these:
https://www.amazon.co.uk/Magiin-Storage-Removal-Automotive-Jewelry/dp/B07QQWYGF5

not sure if these will be the right size, just giving you an idea of what they look like.

Line it up and whack it hard with a heavy hammer. You want to use as few hits as possible to avoid damaging the pin if you want to reuse it.

You really need the punch to be the right size so it can push it all the way through.

Brilliant, thanks for clearing that up! I'll see what I can find that's similar.

 

[stevebm1]

I have used nails in the past to get those buggers out,you have to be careful not to damage the plunger itself though

 

[ronsplooter]

Check the lengths of the old plunger your removing Vs the new Bally one you're thinking of using. If they're about the same then I'd stick with the originals and just re-bevel the end. If the Bally ones are shorter then I'd also not bother as you'll get different flipper travel

 

[Rob zombie]

I might try these. But there is a proper Silverline set of pin punchers on Amazon that's only £6, but will take two weeks to arrive.

 

[Rob zombie]

Check the lengths of the old plunger your removing Vs the new Bally one you're thinking of using. If they're about the same then I'd stick with the originals and just re-bevel the end. If the Bally ones are shorter then I'd also not bother as you'll get different flipper travel

Yes they are slightly different lengths. The new Bally ones are a bit longer. The original ones (if they are original? It had incorrect coils fitted) were almost falling out of the coils are their full travel. But then again, the coil sleeves looked like this...

 

[Rob zombie]

 

[Rob zombie]

Oh crap. I just realised the hole on the old plastic part is bigger than the new one which will introduce play into the travel.

 

[Rob zombie]

Ok so the other option is to keep the old arms, polish them up and swap them with the arms from the top flippers.

Looks like I will have a complete Bally flipper rebuild kit for sale shortly