I thought I'd show everybody how I attach the power cord to the HV cage. The previous "technician" had replaced the cord and used JB Weld to hold in the original drilled out rivets. Of course he used way too much and I had to grind out a lot of the JB Weld.
I get the small plastic spacers and rivets from my local ACE hardware store. They are in those bins that are along the hardware aisle. I used plastic spacers that are 1/4 long, 1/4 diameter, with a #6 screw hole. The rivets are 1/8 diameter and 3/8 long. The rivets are a solid shank except for the last 1/16 inch or so.
I use my heat gun to gently soften the plastic ears and insert the plastic spacers into the plug. If you have a keen eye, you'll see that one of the spacers is for a 4-40 screw while the other is for a 6-32 screw. Later on I removed the 4-40 spacer and inserted a 6-32 spacer. A 4-40 spacer is too small for the 1/8 rivet to pass through.
I also use a 4-40 fender washer under the head of the rivet. Here you can see how much of the rivet needs to protrude through the HV cage. Not much at all.
Once the rivet with the washer is in place, I put the head of the rivet on my bench vise anvil and support the HV cage using empty chip dip containers stacked to the correct height to have the HV cage level. I then use a small tack hammer and a center punch to begin to flare out the rivet. The center punch is the type that is pretty "blunt". Once the rivet firmly set with the center punch, I use a domed shaped bolt head to finish flatten out the rivet. You don't have to beat these rivets real hard. Just some gentle taps with the tack hammer. Here are the tools I use to set the rivet.
Here is what it looks like when I'm done setting the rivets.
And the finished product.
