This is the finished part. Right now the original cracked setscrew is still working, but the day may come when the small piece between the cracks brea...
The photo shows the 40 year old panic bar door hardware on our church doors. We had a problem that left us wondering for a bit if we would need to buy new door hardware for $600, but solved the problem inexpensively.
Sunday mornings we "lock" this door open by pushing the bar toward the door and turning a hex key clockwise in the hole shown. That causes the knuckle in the panic bar to remain pulled inward in the direction of the door, as you can see just above my hand. Someone had turned the hex key counterclockwise. When the door did not "unlock," he got a big pliers and began to force the hex key. The internal parts were bound so tightly that he cracked a part inside. This Instructable will show how to make a replacement part.
The first step was to remove the cover over the mechanism. You can see two screws on top of the cover. There are two more on the bottom of the cover, too.
Bio:I miss the days when magazines like Popular Mechanics had all sorts of DIY projects for making and repairing just about everything. I am enjoying posting things I have learned and done since I got my...read more »