The Ford Barn

Bash1931 · 07-18-2023, 07:44 AM

I am in the process of installing a new wiring harness in my Victoria. It appears that one of the brass contacts in the disc has sunken down into the bakelite of the disc. Rather than starting all over again, does anyone know if it is possible to purchase just the disc portion of the harness? If not, is it possible to remove the disc, ream out the area above the contact and fill in behind the contact to keep it at the correct depth?

old31 · 07-18-2023, 07:56 AM

Bash, could you send in a photo of your problem?

Who did you purchase the harness from?

burner31 · 07-18-2023, 12:42 PM

You could always build it with solder then dress it down with a fine file to the desired level.
But like Old31 said...a picture could help.

Bash1931 · 07-19-2023, 06:33 AM

This is my first attempt to upload a photo, so we'll see if it works. I circled the contact which is sunk down. It looks melted. I'm surprised this piece isn't replaceable, given how the wires are easily removed from the back.

I like the solder idea; I bet that will work.

I also can't figure out why it is sunk in like that. It couldn't have come that way from the retailer as I would have noticed it. I am guessing it is the contact which goes to the generator, and if so, it must have heated up and sunk in?

nkaminar · 07-19-2023, 08:27 AM

Well, you did a good job at uploading the photo.

If you fill it in with solder, use a hard solder like eutectic tin-silver or solder a brass cup at the top.

Can you return the defective harness for a replacement?

Can you heat the plastic and push the contact back into position? Or heat the plastic and push the contact through and epoxy it into place?

The generator does not go through the light switch. Check for a short somewhere or heavy current drain for that contact. Where does that wire go to? A defective contact can generate a lot of heat and melt the plastic so it may not be heavy current.

When you get it fixed and go to put it back together, use a little electrical grease on the contacts.

Kurt in NJ · 07-19-2023, 09:46 AM

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It melted because there is a bad connection in that area, the heat melted the plastic, what does the other side look like?
The best repair would be to find original or old production Bakelite one and solder the wires on.
If it is a recently purchased item return it or see if they would send you a new plate

Bash1931 · 07-19-2023, 11:35 AM

Thank you so much for the great suggestions!

Tim Ayers · 07-19-2023, 01:50 PM

Quote:

Originally Posted by Kurt in NJ

It melted because there is a bad connection in that area, the heat melted the plastic, what does the other side look like?
The best repair would be to find original or old production Bakelite one and solder the wires on.
If it is a recently purchased item return it or see if they would send you a new plate

This. The current repops aren't good.

Find an original or older replacement one. They are out there.

v8fordman · 07-20-2023, 09:41 PM

Contact me at [email protected]. I should have an original one but won’t be back home until Sunday.

Model "A" Fords · 07-21-2023, 06:02 AM

Quote:

Originally Posted by Bash1931

I am in the process of installing a new wiring harness. It appears that one of the brass contacts in the disc has sunken down into the Bakelite of the disc. does anyone know if it is possible to purchase just the disc portion of the harness?

Bert's Model A store sells "original" along with new parts and likely has an original piece in stock.

https://modelastore.com/

Bigsnapper43 · 07-21-2023, 07:17 PM

Give me a call. Ihave several original cut off plates. 740 658 3495.

BillCNC · 07-22-2023, 09:01 AM

Mine did that and I fixed it by pushing the brass slug back into possision and glueing it back with CA. A couple weeks later, it did it again.

The problem was my Halogen headlight were drawing to much for the crappy plastic pucks that they sell with the new harbnesses these days.

I removed the Halogen headlights and put in stock bulbs and that solved my issue. What ever slug got melted, thats the wire to check.

Regards
Bill

rotorwrench · 07-22-2023, 05:13 PM

A lot of folks with halogen bulbs could experience that type of failure. Some are going to the big LED headlight bulbs to cut down on amps and still get a bright high beam. They are kind of expensive though.

BillCNC · 07-23-2023, 12:33 PM

Quote:

Originally Posted by rotorwrench

A lot of folks with halogen bulbs could experience that type of failure. Some are going to the big LED headlight bulbs to cut down on amps and still get a bright high beam. They are kind of expensive though.

Yup, that's why I went with $11.70 for (3) pairs of the original bulbs. I refuse to drop $100 for a pair headlight bulbs. I'd at least try to make some LED bulbs first using Cree LED's.

Regards
Bill

nkaminar · 07-23-2023, 05:25 PM

To use the halogen bulbs the socket and reflector have been changed out. To use the LED bulbs the sockets and reflectors have to be converted back to stock.

Rob Doe · 07-23-2023, 05:57 PM

I bought a new contact plate from Tyree Harris at 804-556-5200. It is the proper thickness too. He was polite, quick, and even sent the part, trusting me to send back a check. Go for it.

CT Jack · 07-23-2023, 07:47 PM

You said you are installing a new wiring harness and do not want to start all over again. Looking at the defective contacts I highly recommend you send this harness back to your resource. Trying to fix it will ultimately cause problems down the road which could result in shorting or blowing a fuse.

TomInCologne · 07-24-2023, 04:17 AM

i wonder why these are made from plastic, wouldn't an epoxy resin be better? in our company, we use epoxy resin to form inductors under vacuum. would that be a better solution?

nkaminar · 07-24-2023, 07:06 AM

There are basically two types of plastic used for injection molding, one is thermoforming and one is thermosetting. The thermoforming plastic melts and then hardens in the cooled mold but it can be re melted. The thermosetting plastic goes through a chemical reaction when heated and cannot be re melted.

Epoxy is a plastic that undergoes a chemical reaction but doesn't depend on heat, although the reaction progresses faster when heated and can be almost stopped when put in a freezer.

old31 · 07-24-2023, 09:36 AM

No way would I waste time trying to repair that harness. Send it back.

Brattons has a good new harness that has all the wires soldered. Unlike Snyders unsoldered wires.

07-18-2023, 07:44 AM	#1
Bash1931 Junior Member Join Date: Jun 2018 Posts: 5	Light Wiring Disc I am in the process of installing a new wiring harness in my Victoria. It appears that one of the brass contacts in the disc has sunken down into the bakelite of the disc. Rather than starting all over again, does anyone know if it is possible to purchase just the disc portion of the harness? If not, is it possible to remove the disc, ream out the area above the contact and fill in behind the contact to keep it at the correct depth?

07-18-2023, 07:56 AM	#2
old31 Senior Member Join Date: Jan 2016 Posts: 2,103	Re: Light Wiring Disc Bash, could you send in a photo of your problem? Who did you purchase the harness from?

07-18-2023, 12:42 PM	#3
burner31 Senior Member Join Date: Dec 2014 Location: Shawnee, Ok Posts: 3,471	Re: Light Wiring Disc You could always build it with solder then dress it down with a fine file to the desired level. But like Old31 said...a picture could help. __________________ Keith Shawnee OK '31 SW 160-B

07-19-2023, 08:27 AM	#5
nkaminar Senior Member Join Date: Jan 2012 Location: Western North Carolina Posts: 3,900	Re: Light Wiring Disc Well, you did a good job at uploading the photo. If you fill it in with solder, use a hard solder like eutectic tin-silver or solder a brass cup at the top. Can you return the defective harness for a replacement? Can you heat the plastic and push the contact back into position? Or heat the plastic and push the contact through and epoxy it into place? The generator does not go through the light switch. Check for a short somewhere or heavy current drain for that contact. Where does that wire go to? A defective contact can generate a lot of heat and melt the plastic so it may not be heavy current. When you get it fixed and go to put it back together, use a little electrical grease on the contacts. __________________ A is for apple, green as the sky. Step on the gas, for tomorrow I die. Forget the brakes, they really don't work. The clutch always sticks, and starts with a jerk. My car grows red hair, and flies through the air. Driving's a blast, a blast from the past. Last edited by nkaminar; 07-19-2023 at 08:39 AM.

07-19-2023, 09:46 AM	#6
Kurt in NJ Senior Member Join Date: May 2010 Location: on the Littlefield Posts: 6,159	Re: Light Wiring Disc Sponsored Links (Register now to hide all advertisements) It melted because there is a bad connection in that area, the heat melted the plastic, what does the other side look like? The best repair would be to find original or old production Bakelite one and solder the wires on. If it is a recently purchased item return it or see if they would send you a new plate

07-19-2023, 11:35 AM	#7
Bash1931 Junior Member Join Date: Jun 2018 Posts: 5	Re: Light Wiring Disc Thank you so much for the great suggestions!

07-20-2023, 09:41 PM	#9
v8fordman Senior Member Join Date: May 2010 Location: Lexington, NC Posts: 861	Re: Light Wiring Disc Contact me at [email protected]. I should have an original one but won’t be back home until Sunday.

07-21-2023, 07:17 PM	#11
Bigsnapper43 Member Join Date: Feb 2023 Posts: 84	Re: Light Wiring Disc Give me a call. Ihave several original cut off plates. 740 658 3495.

07-22-2023, 09:01 AM	#12
BillCNC Senior Member Join Date: Aug 2017 Location: SoCal Desert Posts: 826	Re: Light Wiring Disc Mine did that and I fixed it by pushing the brass slug back into possision and glueing it back with CA. A couple weeks later, it did it again. The problem was my Halogen headlight were drawing to much for the crappy plastic pucks that they sell with the new harbnesses these days. I removed the Halogen headlights and put in stock bulbs and that solved my issue. What ever slug got melted, thats the wire to check. Regards Bill

07-22-2023, 05:13 PM	#13
rotorwrench Senior Member Join Date: Jun 2010 Location: San Antonio, Texas Posts: 16,436	Re: Light Wiring Disc A lot of folks with halogen bulbs could experience that type of failure. Some are going to the big LED headlight bulbs to cut down on amps and still get a bright high beam. They are kind of expensive though.

07-23-2023, 05:25 PM	#15
nkaminar Senior Member Join Date: Jan 2012 Location: Western North Carolina Posts: 3,900	Re: Light Wiring Disc To use the halogen bulbs the socket and reflector have been changed out. To use the LED bulbs the sockets and reflectors have to be converted back to stock. __________________ A is for apple, green as the sky. Step on the gas, for tomorrow I die. Forget the brakes, they really don't work. The clutch always sticks, and starts with a jerk. My car grows red hair, and flies through the air. Driving's a blast, a blast from the past.

07-23-2023, 05:57 PM	#16
Rob Doe Senior Member Join Date: Apr 2021 Location: Central Illinois Posts: 494	Re: Light Wiring Disc I bought a new contact plate from Tyree Harris at 804-556-5200. It is the proper thickness too. He was polite, quick, and even sent the part, trusting me to send back a check. Go for it. __________________ "It ain't what you know for certain that gets ya in trouble. It's what ya know for certain that just ain't so!"

07-23-2023, 07:47 PM	#17
CT Jack Senior Member Join Date: May 2010 Location: Hebron, CT Posts: 432	Re: Light Wiring Disc You said you are installing a new wiring harness and do not want to start all over again. Looking at the defective contacts I highly recommend you send this harness back to your resource. Trying to fix it will ultimately cause problems down the road which could result in shorting or blowing a fuse.

07-24-2023, 04:17 AM	#18
TomInCologne Senior Member Join Date: Aug 2021 Location: Germany: Cologne and Witten Posts: 305	Re: Light Wiring Disc i wonder why these are made from plastic, wouldn't an epoxy resin be better? in our company, we use epoxy resin to form inductors under vacuum. would that be a better solution?

07-24-2023, 07:06 AM	#19
nkaminar Senior Member Join Date: Jan 2012 Location: Western North Carolina Posts: 3,900	Re: Light Wiring Disc There are basically two types of plastic used for injection molding, one is thermoforming and one is thermosetting. The thermoforming plastic melts and then hardens in the cooled mold but it can be re melted. The thermosetting plastic goes through a chemical reaction when heated and cannot be re melted. Epoxy is a plastic that undergoes a chemical reaction but doesn't depend on heat, although the reaction progresses faster when heated and can be almost stopped when put in a freezer. __________________ A is for apple, green as the sky. Step on the gas, for tomorrow I die. Forget the brakes, they really don't work. The clutch always sticks, and starts with a jerk. My car grows red hair, and flies through the air. Driving's a blast, a blast from the past.

07-24-2023, 09:36 AM	#20
old31 Senior Member Join Date: Jan 2016 Posts: 2,103	Re: Light Wiring Disc No way would I waste time trying to repair that harness. Send it back. Brattons has a good new harness that has all the wires soldered. Unlike Snyders unsoldered wires.