Here is my method for replacing the broken pricker on a Handi Keropet lantern. However, this method can be used for many other makes of lanterns. Materials. · Original cleaning needle. The main body of the cleaner is 1.79mm dia (major length). The crimped end (holding the pricker) is 1mm dia. · 1mm dia brass tube with nominal wall thickness of 0.3mm · 27 gauge hypodermic needle · Replacement pricker wire (0.15mm – 0.17mm) in my case the pricker wire is 0.15mm stainless steel spring wire. · If you need to make one from scratch it can be done using either 2mm or 5/64” dia brass for the main rod. · I have had success threading the end of the rod 9BA (65.1TPI). Method 1. Measure the overall length of the brass rod (excluding the pricker). I find they vary slightly between lanterns. 2. Cut off the 1mm end or the rod (which holds the broken pricker) and square of the end. 3. Using a lathe centre drill the brass rod. 4. Use a 1mm dia drill to drill a hole in the rod with a depth of 5 to 6mm. I use a pin drill to hold the 1mm drill. The pin drill is loosely held in the drill chuck on the lathe as a guide only. With the lathe running I control the drill by hand to drill the hole (broke too many drills determining this). 5. Insert the 1mm brass tube into the drilled hole and mark the length measured in step 1. Cut the 1mm tube to length. Don’t use side cutters, score the tube with a sharp knife blade, then either side of the score hold the tube with pliers and flex until the tube snaps. 6. Melt the plastic end off the hypodermic needle. Insert the hypodermic needle into the 1mm brass tube and cut to match the length of the 1mm brass (don’t use side cutters, use method described in step 5 ). 7. Check the overall length to match measurement taken in stage 1. 8. The pricker; take the piece you have chosen and make a small right angle bend at the base. Tail will be approx 0.5mm long (stops the wire pulling out after crimping) Remove the 1mm brass with the hypodermic needle and insert the new pricker wire. Allow excess to be trimmed later. 9. Reassemble and make sure all the pieces are pushed together (recheck length) then crimp the assembly in place. Remove any burs. My crimper is a pair of pliers with a 1.5mm hole drilled through the jaw face. The tips of the jaws are ground so I can place the pliers in a vice if necessary. 10. Insert the assembled rod into the generator and trim the pricker to length, remove bur. Done.
@Julian Whittaker I believe you are correct. The narrow section is a tube and pressed in. How it's held I'm not sure and haven't been able to pull one out.
