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PostPosted: Thu Aug 04, 2005 4:53 pm 
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Joined: Tue May 27, 2003 12:44 pm
Posts: 9020
Location: Oceanside, California
Cam replacement:

Drill off the flaired end of the old pin, then punch it through with a straight punch or pin of similar diameter (3/16"). Drill using a 3/16" - 1/4" bit and wobble (especially the smaller bit sizes) the bit around to thin the flair, but avoid drilling the aluminum casting at ALL costs. You can wedge a phillips head driver in the opposite end of the pin to help keep it from spinning whill drilling.

Get the cam replacement kit with screw in pin and install.

or... if using the original flair pins...

Place a large center punch in a vise pointing straight up and keep the end nearly flush with the top of the vise. Place the casting, cam and and pin over the punch in the vise. With the punch centered in the new pin and the pin centered in the casting, smack the top of the pin with another punch and hammer. This will flair both ends at once. Look at the pin, center and repeat. Hammer till snug in the casting, but avoid over doing it as you can pinch the casting and possibly fracture it. The best punch is actually a piano tuning key. They have broad flairs with a small square bit on the end that helps keep the punch centered.

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Matt Miller
Director of Parts and Accessory Sales
Hobie Cat USA


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