[Contributed by Mondial]

I have been working on my 38-116 tuning mechanism and found that the tuning action was stiff due to misalignment of the RF chassis to the tuning mechanism. Even after replacing the rubber mountings, the problem persisted because of the distorted and hardened rubber coupling on the tuning cap shaft.

This coupling was originally soft and flexible to allow for movement between the RF chassis and the tuning mechanism. So I decided to try and rebuild the coupling. Luckily the identical rubber sheet material is available from Mcmaster:

http://www.mcmaster.com/#8698k73/=tgwj3s

The first step was to remove the existing rubber, rivets and brass eyelets without damaging them. There was no way to save the two large steel rivets so they were drilled out. Then the rubber was chipped away around the brass eyelets so there was enough room to straighten the flared over end and remove them without damage so they could be reused. After disassembly the next step was to cut new rubber disks from the sheet of material. This was done with a gasket circle cutter and a punch for the rivet holes.

To replace the rivets, one could just use a 10-32 machine screw, but I chose to make a reproduction replacement out of brass rod.

After reassembly, here is the final product.