The sound of the original DC horn operating on the clipped AC through a rectifier and capacitor filter, just wasn't satisfying me. It doesn't sound the same as operated from a battery. There had to be a way to make the horn louder. After all it is a safety issue. If you blow your horn, you want to be heard.
I had purchased a 12VAC horn from India via eBay. It is a nice build quality, but of course it was made for a Primavera, and the hole pattern was too small to fit the unique 100 Sport. I had pondered this for months, and really didn't give it any action until this rainy weekend.
Since the reproduction 12VAC horn hole pattern was smaller, I could potentially graft it to the original 100 Sport horn cover. This would require removing the rivets, and make a paper pattern of the adapter. I could then cut out the adapter ring from whatever metal I happened to have laying around the shop. I could use the same soft-aluminum wire to make replacement rivets to hold the whole assembly together. I had nothing to lose, the DC horn could still be put back together if I wasn't satisfied... I had already taken it apart once before.
Things came apart easily. No photos taken during the Dremel tool cutoff disc work.
I got to work drafting the paper model of the adapter ring.
Here are all the parts that will be used.
After crafting each aluminum rivet one-by-one, we have a completed AC horn mechanism grafted to the original horn cover. It sounds nice and loud.
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