Subject: Re: Brake overhaul - levers
Hi Chaps
Some thoughts:
I am not comfortable with making these items as castings. Originally they would have been forged so personally I think it would be better to go to a specialist welder the re-do the eyes on the original ones. Perhaps with a X-ray test afterwards to confirm integrity.
If you are forced to have some bits machined out of solid, look at various structural steel sections such as RSJ's and U sections to see whether new levers can be carved out of a standard section. These will have been hot-rolled so the grain of the material will be better than something machined out of a solid lump.
I am not a mechanical engineer or metallurgist so do not rely on my inputs without further advice...
Colin M34