[hypoxia]

But, none the less, not a single pull on my handle doesn't make me cringe...and every single time, I listen for a crisp actuation. I also was admonished, on the very first visit to Newell, to NEVER pull AND HOLD those handles; they said THAT'S what burns them out. Your discovery, somewhat dilutes that theory!

Any action that pushes the microswitch arm powers that little latch motor, I get nervous every time I open a bay door.  I'm looking at push button switches to install and eliminate that whole monkey motion switch.  I'm working on a show & tell to add on here today, hopefully.  Waterproof momentary action non-illuminated small pushbutton.  SPST or DPST

[hypoxia]

The latch handle is a TriMark 030-2000 (Patent 6708537) adapted by Southco for their electric latch.  I propose drilling a hole in the handle assembly (preferred) or the bay door to add a push button momentary switch to actuate the latches.  That would eliminate all of the electrical & mechanical action the handle currently has which is THE problem.  The handle movement would be disabled & it would just be used to pull the door open.  On the handle I see two possibilities; underneath the moving part of the handle OR to the side of the handle where a key lock would normally be.  On the handle photo you can see the key lock cylinder location.

The pushbutton switch would be waterproof, SPST or DPST, low profile.  I'm open to suggestions.  There is a fair amount of space underneath the moving part of the handle for a switch to be added, that is my preferred location if I can find a switch that fits.  Drilling a hole in the bay door beside the handle is an easier task as well as making the switch size less relevant, not sure about the aesthetics.  
                   

TriMark Bay Door Handle 030-2000_Rev 12.pdf Size: 687.01 KB  Downloads: 0

   

[hypoxia]

Microswitch removed, pushbutton switch installed!  I found an Otto pushbutton switch in my airplane parts bin so I installed it and will order more and do all of the bays.  edit:  I ordered Otto P3-31111W pushbutton switches.  They are commercial duty, double break, watertight to IP68S & IP69K and have a red button with a 2.5 pound push.  I will mount them about 0.5" lower than the first one.  This change will enable using the handle to open a bay without ever burning out a latch motor.

The Otto switch I found in my parts bin was from the mid 1970's used in some Air Force flying machine I worked on; F-101, F102, F-106, F-4, T-33, EB-57E, KC/RC/WC-135 or something.  They have been in business for a long time.

               

Bay Door Handle Otto P3 Pushbutton Bulletin.pdf Size: 429.63 KB  Downloads: 2

Otto P3-31111W Pushbutton Switch Specs Bay Door.pdf Size: 648.23 KB  Downloads: 2

[hypoxia]

The final solution was removing the micro switch and the arm that pushed on the microswitch.  I milled the assembly to provide a smooth surface, drilled a 5/8" hole and mounted a pushbutton switch.  All 9 bay door handles have been modified.  The pushbutton switches are Otto P3-31111W which are commercial rated and watertight to IP68S and IP69K specs.  It took about 1 hour per door  to remove, modify and reinstall the handle assembly.

The switch button is easily accessible and a momentary push unlatches the bay door latches.  The handle can be pulled for as long as desired without concern of burning out a latch motor.

               

[RobSC]

Nice job and the slightly hidden location is ideal.  

Do you plan on replacing the Southco latches also?  I've had latch issues lately and might address those first.

[hypoxia]

Nice job and the slightly hidden location is ideal.  

Do you plan on replacing the Southco latches also?  I've had latch issues lately and might address those first.

Not at this time.  They are currently working fine and don't expect any more problems unless the little motors have already been overheated and damaged.  I would be looking for a source for the ~$5 motor, the plastic housing was slightly melted but useable.  The odor of the burnt motors was not electrical but smelled like a cigarette ashtray.  I have 6 new latches to use if any more fail.

What is your symptom?

[RobSC]

Nice job and the slightly hidden location is ideal.  

Do you plan on replacing the Southco latches also?  I've had latch issues lately and might address those first.

Not at this time.  They are currently working fine and don't expect any more problems unless the little motors have already been overheated and damaged.  I would be looking for a source for the ~$5 motor, the plastic housing was slightly melted but useable.  The odor of the burnt motors was not electrical but smelled like a cigarette ashtray.  I have 6 new latches to use if any more fail.

What is your symptom?

Sometimes, the latch on one end will not release the bay door when the handle is pulled.  I can a hear a click at the latch, but it will not unlock.  I have to use the emergency pull cable to open the door.  That same latch will sometimes unlock while traveling.  The door doesn't open thankfully, as the other latch keeps it locked.  I tried some minor adjustments on the striker, but it didn't make any difference.  This bay door is the one for the generator blower, so I can't access it from the other side to view when the latch and striker while closed.