Replacing 800 keyboard plungers

[Gunstar]

Well, I've finally started upgrades and mods and repairs on my 800, I've many on the list and was just waiting until I had time to do them all at once over a few days. I'm starting with my 800's keyboard which has several broken plungers, even though all the keys are working. I'm using what look to be NOS replacements I was given by @ACML

 

What is the best way or best tool for pulling the mechanical plungers on a HI-TEK 800 keyboard? I managed to get the space bar plunger removed with a thin, cheap, pair of tweezers, but it's not the best way and as you can see in the picture below, I ended up breaking one side of an old plunger for the SHIFT key. You can see a replacement plunger next to it that I'm using; it has little tabs on the bottom to hold it in place once inserted all the way, and these need to be pressed in for removal.

Edited April 18, 2020 by Gunstar

[_The Doctor__]

The best way I have found is to have the keyboard extremely warm for a period of time, hours into it being nearly hot, using a key loop removal tool to deftly pull the cap.  When doing it cold or slowly, it either cracks in one of the corners or breaks... I've learned not to disturb fully working 800 keyboards and only vacuum/clean them with credit card hook to snag lint etc...

[Gunstar]

@_The Doctor__Well, as far as removal, I'm only doing ones that are already cracked or broken, and don't care if they crack or break more as long as I can pull them out. Slipping a new one in is easy, though I will take your advice on getting the new plungers (and base) very warm when inserting to avoid cracking, but insertion is as easy as lightly pressing down on the top with a finger, from my one experience with the space bar I managed to replace.

Edited April 18, 2020 by Gunstar

[Gunstar]

@_The Doctor__ , I found, as you said, I was being too slow and meticulous. I put it out in the sun for a while to get it warm, but then realized I'm not going to be able to do what I need to do before it cools off too much anyway. In the end I found that just using my needle-nose pliers and grasping a plunger side-wall, while holding the base of the keyboard, I just pull straight up quickly, and they come out with ease and nothing breaks. 

Edited April 18, 2020 by Gunstar