2 pole 6 position rotary switches [resolved]

[NightFlight]

The one selected for my fine attenuator is not always making proper contact in all positions. I've tried every sort of adjustment and come to the conclusion that I have just have to suck it up and replace it.  To the best of my knowledge, I figure this one switch is likely out of factory tolerance.  I'm willing to return it if required for inspection.

I've put it off because it means removing and redoing the resistor network which looks like it will be a real PITA. Its either I put up with a random channel imbalance, fiddle with a light touch to get it right or just order a replacement.

Should I request the resistors too? I suspect I may end up cooking/damaging at least one getting them out of there. Maybe the alligator heat sink trick could help me save the resistors?

I'm drafting up the warranty replacement request right now, but figured I should get an opinion here before firing that off.

[Paul Birkeland]

Can you post a photo of the switch as it sits currently? 

You are correct that the switch and resistors should both be replaced.

-PB

[NightFlight]

I can. But... I don't think there will be any sort of visual indicator that would show the wiper connectivity issue.

[Paul Birkeland]

Is it the 2nd to loudest position that's causing the problem? (only on one channel)

[NightFlight]

The wiper is engaged on the most affected contact in the photo (-4.5dB). Same issue with -6.0dB, but the remainder of positions seem to be fine.

[Paul Birkeland]

Before going through the trouble of replacing the switch, you may want to try to bend the contacts on those positions to be slightly tighter.  I recommend doing this with a toothpick.

-PB

[NightFlight]

Well, you can chalk up another one. I used a small flat head driver, but I was able to crunch down the wipers a hair. I almost screwed one up. It's a bit fiddly to get it right.  Thanks Paul!