What size circlip/starlock washer?

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Am a bit puzzled. Am wanting to use a circlip or starlock washer to keep a metal connecting rod from slipping out of a brittle plastic clip on the van’s hab door lock. The rod measures 2.22mm. I’ve tried a selection of circlips and starlock washers and they are either too large or too small. I’ve looked at circlips for use with circlip pliers, which I have but wondered what the optimal internal diameter clip should be?
IMG_1609.jpeg
 
Personally I would use an appropriate size 'wire rope clamp'. A 2mm might fit if not a 3mm. I have them for terminating flying wires in theatres, but while more bulky, they wouldn't go anywhere if appropriately torqued. I buy mine from a local lift engineering company, but they are available on line.
 
Can you not get a replacement plastic part?
No. It’s a tiny plastic nib that holds the rod in place. The old one had broken and someone had tried a repair with a cable tie. It had worked for a while but eventually, it failed. So I bought an entire Hartal 2 point lock assembly and fixed the lock. However, the lock has broken in a different place but I want to ensure that I don’t need to rely on the plastic nib in case it breaks. It is brittle and it wouldn’t take much to break it.
I’d post photos of the offending part but the van is in storage.

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Last edited:
A 2mm star lock should fit it will just need a bit of pressure to push it on.
I can see pressure should do it but I need to find a way to hold the rod end when in situ and be able to assert enough pressure. Have seen a star lock tool somewhere but not sure how it would fit a 2mm washer.
 
I can see pressure should do it but I need to find a way to hold the rod end when in situ and be able to assert enough pressure. Have seen a star lock tool somewhere but not sure how it would fit a 2mm washer.
Can you not hold the rod with some long nosed pliers or visegrips?
 
You need a clip similar to this.

Screenshot_20240331-154948.png


Put the rod into position.
Put the hole over the open end of the rod.
Clip the left hand end over the rod.

These are so common on cars but I can't find a link anywhere.
 
Am a bit puzzled. Am wanting to use a circlip or starlock washer to keep a metal connecting rod from slipping out of a brittle plastic clip on the van’s hab door lock. The rod measures 2.22mm. I’ve tried a selection of circlips and starlock washers and they are either too large or too small. I’ve looked at circlips for use with circlip pliers, which I have but wondered what the optimal internal diameter clip should be? View attachment 881328

You should be measuring the bottom diameter of the groove. Either the star washer or the E clip that will fit
 
Personally I would use an appropriate size 'wire rope clamp'. A 2mm might fit if not a 3mm. I have them for terminating flying wires in theatres, but while more bulky, they wouldn't go anywhere if appropriately torqued. I buy mine from a local lift engineering company, but they are available on line.
Going to search on line for this. Thanks.

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You need a clip similar to this.

View attachment 881370

Put the rod into position.
Put the hole over the open end of the rod.
Clip the left hand end over the rod.

These are so common on cars but I can't find a link anywhere.
 

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