It's taken a few months to finally get the crank fixed and report back to you. I offer the following to generate ideas. It's not an easy fix but it certainly works well.
Based on the comments here in the forum, I took your advice and looked at a non-LMC solution.
Here is what I and two friends came up with. I'm sorry to say I don't have pictures. I hope my description will be adequate.
Given the bad replacement part scenario we decided to replace the pawl and the clutch as both were broken. The window is now cranked using a 1/2 inch ratchet.
We cut off the clutch from the handle mechanism, essentially leaving a hole.
The clutch piece that normally engages the regulator was fabricated using a pipe coupling of about 1 inch diameter. This pipe coupling fits inside the existing handle. This coupling was put on its end side by side with the clutch piece. My friend who is a very skilled welder and metal fabricator, looked at the clutch and essentially cut away side pieces of the pipe and left behind a heavy duty piece of pipe that loosely fits on top of the regulator, but actually has more contact with the regulator than the original clutch.
This clutch replacement extended through the handle where it was welded to a washer we used as a spacer ( I think he cut the coupling about an 1/8 inch too short). The overall length of our fix, matched the original length.
On the outside face of the handle, we took an old 1/2 socket (thick walls) and trimmed off the socket end. We then took a very large washer that snugly fit around the diameter of the socket.
The washer diameter was ground down enough that it would fit inside the handle. The washer surrounding the socket and the remainig half of the socket, were welded together, then fit thru the hole in the handle and then welded to the washer side of the fabricated clutch.
What you see now, as you crank the window is the 1/2 inch socket hole. We have to go back and fabricate some way to attach the old crank handle to the original faceplate. We are thinking of using wire to do this.
Yes, I realize that this is not original. And that currently the ratchet hole is subject to the weather. Any holes in the cover plate and to the outside have been sealed with waterproof caulking. The inside area was lubed with lithium grease while the side to the elements was lubed with oil.
I've painted the exposed side (ratchet hole) with a rust resistant black paint. I'll add a touch of green, when I get a chance. But right now I like the "black" look.
I bought a 1/2 inch / 3/8 combination ratchet at Tractor Supply with a very long handle. This makes it easy to open.
It took a while to get it done, but it is functional and it works for me!
Clearly, this isn't an easy fix to make, but if you have access to the welding / cutting skills, it could be considered an alternative approach; or at least get you thinking in a new way.
Costs:
Old 1/2 socket .50 (from a place here that sells old tools and materials (REstore if you have one)
1 inch inside diameter washer (I had one)
Piece of pipe with the coupling (I had it behind the house)
Other washer (I also had).
Up until the time my welder friend came by I didn't know I was going to need or use the pipe. I had some other ideas that fell quickly away. I did have the socket side figured out however. Paul came up with the idea to cut into the pipe, we had a coupling that we used instead of cutting the pipe.
All of this because of bad replacement parts! THANKS for the heads up and terrific advice!!!
Yes, I paid my welder friend. We also had some pizza! The amazing part of all this is that he did this in my driveway at night.
