I was always concerned that my brake light didn't come on until fully dressed. So when I rebuilt my pedal cluster I installed a new mechanical brake switch hoping that it would solve the problem (40 year old switch?) I completed the rebuild put it all back together and there was no real change to the brake lights. So I too everything out and tried to find if I was missing something, or needed to Mcgyver a solution.
Here's what the pedal cluster should look like:
When I adjust the nut for the brake switch, the large washer becomes very floppy. So I added an extra nut in order to 'sandwich' the larger washer along the threaded shaft
Here's what I did:
I reinstalled everything and made some final adjustments, now the brake lights come on with minimal effort. I don't know if all mechanical switches take such long travel to close the circuit, but this was my scenario/solution and I am very happy with the results.
