Quite some time ago we discussed in another thread the high cost ($16 IIRC) for the hensley replacement spring plunger WD bar retainers. It was suggested by another member that we try some alternatives here:
After carefully studying a new Hensley piece against these offerings, it became obvious that there is not an exact replacement. #8945A52 is the closest, but the threads for the grease zerk are different and the plunger is 4mm shorter.
But, at $3.90 vs $16, I was determined to try something, so here we go:
When I replaced my last set of plungers I set them as shallow as I could, while still retaining the WD bars. This way I figured I could get two rounds out of them by coming back and setting them deeper when they would no longer hold the bars in. This pic is this whole summer's trips, proving you can set them shallow.
Now, the plunger in the McMaster-Carr piece is 4mm shorter than the Hensley one, it's base is SLIGHTLY larger in diameter, and it does not have a grease groove in it.
I took the Dremmel, with a sanding wheel installed, set it at a medium RPM and rotated the spinning wheel around the diameter of the base of the plunger, checking it frequently in the Hensley body for proper fitment. I then took a Dremmel cutting wheel and cut a grease groove through the base shoulder and up the length of the plunger:
This is the final result:
I believe, based in my experiment in the first picture that this replacement plunger will work, although, I don't think you can get 2 rounds out of it by setting it deeper. I think you'll have set it almost as deep as allowable without the body contacting the WD bar.
After doing one mod, you could do the rest in about 5 minutes each. Worth it? You be the judge, but I think I'll order up about a dozen of the McMaster-Carr plungers and keep a stash of modified "nipples".
Unless someone knows where I can find longer ones....??????