Has anyone dealt with this one before?
 

The hole in the door jam into which the door jam switch is attached is too large, so that the stock door jam switch will not tighten.

Given that it's job is to provide a ground to complete the interior light circuit, anything short of welding and re-taping the hole won't get the stock switch to work, and epoxies and the like do not provide the conductivity necessary for the circuit. I'm hesitant to weld-- new paint, ect.

Has anyone found a suitable substitute with a larger thread size that could be used? There are many switches out there; this one requires a short button travel. Most I've found have extended buttons, which would bind in the door, or are configured for more than providing a ground. The stock switch looks like this:

http://forums.pelicanparts.com/uploa...1315348909.jpg

I would think that you'd still get enough metal to metal contact even with some epoxy in there to complete the circuit, but just in case, here's a conductive epoxy. The other option I can imagine is a helicoil.



Amazon.com: MG Chemicals Silver Conductive Epoxy, 14g (0.35 oz) : 8331-14G: Electronics

Could you add/tack weld a thin body washer with the appropriate clearance hole between the switch nut and the door jamb?

Do you have the door switch washer?
Pelican Parts - Product Information: 901-615-615-20-OEM

Good point!!!!!!!!!!!

yep--washer in place. rubber cover waiting to be added when issue resolved.

If you look at the diagram in the above link there are two washers, the concave washer and another that goes behind the concave washer.

concave washer : Porsche 911 & Carrera Switches & Motors - Page 3
backing washer : Pelican Parts - Automotive Parts and Accessories - Porsche & BMW

If that's not the issue....That's all I got:)

backing washer?
 

didn't realize there was a backing washer...................

Washer.
 

Hope this helps.

I think It's a plastic washer.

Porsche Porsche 911 1965-1969 Washer 8.4 (2 suggested) (Op…

http://forums.pelicanparts.com/uploa...1315365734.jpg

Jubalation!!!!!
 

It's fixed:

Behold the elegance................

After sorting through all the alternatives, I went with BWD - Door Jamb Switch Part # S227. it's about .050" larger, with a 3/8" shank. Used a tap to clean hole to size, and locktite to keep the sombi*ch from coming loose:

http://forums.pelicanparts.com/uploa...1315431788.jpg
This switch is common to over 6,000 vehicles (see link).

Other switches would also work. If threads in door mounting area are good, suggest you go with stock, and do this only if the threads have gotten loose--crimp wire to this end. You can solder also, but there are plastic parts providing insulation, and too much heat will melt the plastic--ask me how I know.............:D
http://forums.pelicanparts.com/uploa...1315431804.jpg

Sleeve is press-fitted into threaded part, and slides into it as door closes to provide an exact fit. The switch part is contained in sleeve.
http://forums.pelicanparts.com/uploa...1315431824.jpg

All the rest of the switch stuff, i.e., washer, door switch washer, and the rubber cover still fit.

Tested with meter; door closed, switch open. Door open, switch closed.
I had the door off it's hinges troubleshooting the electric window motor (bad motor-R&R'd); fishing the wire was a breeze. Spent 4 hours earlier trying to fish the switch wire through the space with the door attached--that was not a breeze.