I have finally modified the original lever to work correctly with Marushin modelgun.
In the meantime I bought a Dremel rotary tool for various home repairs, and instead of spending another day with files I were able to do lever modification in about 5 minutes.
Summary of all work so far:
- remove metal bracket from wooden stock (there are three screws) before doing any work. Bracket is enough to test-fit on receiver.
- remove lever by pushing pin from the side. Take care as there is a spring that can jump out.
- front of the bracket probably needs some widening. Try to push bracket upside down (to avoid interfering with back part) into place just behind grips, to see if it fits. File as necessary, it should be easier with electric tool, but that part is easy to work on by hand, too. I have done that quite quickly by hand.
- file down the cone part. This probably has to be done by hand, as the shape does not lend itself to tools - other parts of the bracket get in a way. I did that part with a hand file. After each correction I have marked all cone surface with black marker, then tried to push bracket into the hole. Areas that block have marker removed - you know now where to file. This process is VERY time consuming.
- bracket should now fit correctly at the front (U-shaped opening) and back (cone).
- install lever and carefully note how much steel has to be removed, then mark it on the lever (for example by scratching it). As I lost patience with files, I have used Dremel 426 cutting wheel to remove excess material, but keeping the "nose" shape. You need to do it bit by bit, frequently checking if the fit is correct (by installing lever into bracke, without spring but with pin in place). Steel is quite hard so is not easy to cut too much :-) Once it was fitted, the final step was to use Dremel 997 to slightly polish the surface and make it even - the cutting process is very rough, at least in my inexperienced hands ;-)
- install lever into the bracket, putting spring and pin into place. Screw the bracket back onto wooden stock, test-fit.
All the time think about safety! Make sure that the part you work on is secured properly and will not move under pressure, as your tool (file or electric) can slip and hurt you. If using electric tools, wear safety glasses.
The next problem that I have discovered is that stock is wobbly after installation. Fron part of the bracke has too large hole between metal part and wood, and the part on receiver that gets in that hole has about 1mm up/down play.