A new lever was cut from a steel plate and drilled for the pivot…

A new lever was cut from a steel plate and drilled for the pivot & operating rod. A short sleeve was used to prevent the bolt from clamping the levers. The new lever is adjustable by cutting its notch lower. It isn't attached to the original lever so that the catch can move normally, without forcing the inside handle. But the inside handle will now operate the catch at all times, regardless of the condition of the other levers, or the position of the lock.

After some testing, the nut was found to interfere slightly with the lock slide, so the bolt was reversed.

Owner caption January 2011 · Photo 27 of 198