This is a close up of the "HOT" pin. Look at the base of spade closely. Notice the puddle around the base. The metal got so hot it sunk into the bakealite and the thimble lost it's grip breaking contact w/ the copper strip. Click to view attachment
The solution was simple: just a spot of acid core solder from the thimble to the copper and then file it down for proper clearance. Click to view attachment
The trick was how to NOT melt the bakealite any further when soldering. I settled for this and it seemed to work. I emersed the other half in a small bag filled w/ ice & water to act as a heat sink. Click to view attachment The whole job took < an hour once I got the switch on the bench. Easy job!