1959 Power Top System

[Richard M.]

Re: 1959 Power Top System

All of my Plated parts are done. I may take a ride out to pick them up later. it's about a hour each way.

I cleaned up the armature commutator on my lathe. The new flat cleaned surface area will provide better contact and allow full current to pass to the pump system.

I cut in 3 minimal depth passes using my automatic horizontal feed to remove the minimal amount of copper to attain a smooth brush contact surface. I will bevel the brushes to the commutator later during assembly.

I then use 1500 grit paper on a flat backer plate to remove ridges. Then using the backside of a X-Acto blade and thin screwdriver I clean the gaps between segments. A final polishing back on the lathe with the 1500 grit finishes the task. I then did a polish of the shaft ends. Note thrust washers. Quantity can vary with different motors. Altogether this took a little over a hour but should rejuvenate the motor for best hydraulic pump operation.



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[Richard M.]

Re: 1959 Power Top System

I took my ride to get the plated parts. Now ready for reassembly. I took some extra close-ups of some of the original manufacturers marks, some of which I've never seen before.

Rich
edit. At first I Iconified them so as to not giaganticize the post, but the dumb Smartphone switched orientations on some and it's a pain to click "NEXT" as they all don't line up. I full-sized them instead.

[Scott S.]

Re: 1959 Power Top System

Richard, Does your Corvette have the large metal plates that are located vertically behind each seat?
Scott
#2379

[Richard M.]

Re: 1959 Power Top System

Richard, Does your Corvette have the large metal plates that are located vertically behind each seat?
Scott
#2379

Yes, but the were added by a prior owner in 1970 when he bought a Soft Top at Corvettes at Carlisle. But I wasn't the owner then as I was only 16. My car was originally a Hard Top only. I like that look better as I like Coupes, but I'm liking the Soft Top too.

[Bob W.]

Re: 1959 Power Top System

Richard I like you ,like the look of my 59 with the hardtop on.

Bob

[Richard M.]

Re: 1959 Power Top System

Richard I like you ,like the look of my 59 with the hardtop on.

Bob

Here it's Grandson, my '07 White/Red Coupe.

[Richard M.]

Re: 1959 Power Top System

Working on the Motor and Pump Assembly today. My last step got me confused.

Has anyone ever seen what type or wrench is used on the fluid tank bolt? I don't even know how to measure it. A 11/16" open end goes on the big flat and the opposite end. It works, but was there a special wrench for these? The last power top I saw used a slotted head bolt.



I assembled the motor and tested it, very strong. Then I assembled the pump with some Auto trans fluid and tested that. All appears fine so far.


I'll go through the build steps with photos later.

Rich

[Joe M.]

Re: 1959 Power Top System

I used vice grip pliers to remove and re-install the long fluid tank bolt, but my bolt was not re-plated; so it didn't matter to me if it had minor teeth marks. I noticed the end cap on your unit has "L0" stamped on the end. My end cap had "L9" on it. I wonder if that is the date code of the pump unit? My micro switches were dated 10/58. I purchased the power top unit from a vendor since my 1960 had 3 bolts remaining from the original power top unit (3 hydraulic cylinder mounting bracket bolts).

Rich, do you have the special washer that mounts between the dash fiberglass and the toggle switch? I could not find an original, so I fabricated a crude rendition of the original. I don't have all of the tools at my disposal that you do and machine shops charge a small fortune to fabricate a one-off part.


Joe

[Richard M.]

Re: 1959 Power Top System

I used vice grip pliers to remove and re-install the long fluid tank bolt, but my bolt was not re-plated; so it didn't matter to me if it had minor teeth marks. I noticed the end cap on your unit has "L0" stamped on the end. My end cap had "L9" on it. I wonder if that is the date code of the pump unit? My micro switches were dated 10/58. I purchased the power top unit from a vendor since my 1960 had 3 bolts remaining from the original power top unit (3 hydraulic cylinder mounting bracket bolts).

Rich, do you have the special washer that mounts between the dash fiberglass and the toggle switch? I could not find an original, so I fabricated a crude rendition of the original. I don't have all of the tools at my disposal that you do and machine shops charge a small fortune to fabricate a one-off part.

Joe

Joe, The "L0" on this tank cover may be for "1960" as this unit came from a '61.

Yes I'm missing that piece. You did a nice job on yours. I'll have to make one, but probably by hand with drills, files and patience. I'd imagine originals were stamped using a press and special fixturing.

Rich

[Cecil L.]

Re: 1959 Power Top System

That locating washer is pretty much standard on AN panel mounted switches on aircraft.

[Joe M.]

Re: 1959 Power Top System

Where would I look for AN panel-mounted locating washers?

[Cecil L.]

Re: 1959 Power Top System

Surplus store, ebay, Mouser Electronics, possibly Ace Hardware. They're commonly used on just about any toggle type switch with a locating groove for the washer tang.

[Cecil L.]

Re: 1959 Power Top System

Aviation Parts 4 2-Position Toggle Switch 6-Connections, Carling, CH, Free (320

[Richard M.]

Re: 1959 Power Top System

Back to the Power Top assembly work.

I tested, cleaned and re-wrapped the solenoids. I used a fabric tape much like the original type.


I reinstalled all valve fittings. I used a dab of Permatex #2 sealant on the threads. The 1/8 pipe thread plugs are brass replacements. The original steel plugs were destroyed in the rebuild process as they were badly seized. The sealant will help prevent seizure in the future.


After installing the plungers in the valves the solenoids are installed and covers attached using 6 slotted machine screws on each valve assembly. The covers press on the solenoids to create the Ground Path. The Black and Red wires to the solenoids are the +12V power to each. Grounds to each are from the covers.


The Solenoid Valve assemblies are then attached to the frame using 4 panhead slotted screws with integrated internal tooth lockwashers to ensure a good ground. The Top valve assembly is for the Deck Lid. The lower for the Top Frame.


The Pump Assembly attaches to the frame and is held in by its special rubber feet. I'll permanently attach later after a bench test.


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[Richard M.]

Re: 1959 Power Top System

Harnesses and connections to limit/safety switches, solenoid valves and motor now readied for some basic electrical tests. I'll also be using the restored original 40A circuit breaker connected to the 12V source battery.


The test will be to verify each of the 4 solenoids and that they operate individually and sequentially while I manually operate the 2 Deck lid and 2 Top frame limit switches. I'll have to manually operate/bypass the Trunk and Deck lid safety switches. The Pump Motor was already tested so I will leave that out of the test circuit. It will be connected when the hydraulics are assembled later for the cylinder tests with fluid added to the entire system.

Solenoid Valves - Upper is the single Deck lid cylinder, Lower is for the 2 Top Frame cylinders.




Soft Top frame Limit Switch assembly. One switch tells the system that the frame is up, the other when frame is down. This mounts next to the Passenger seat and the long link attaches to the soft top frame. The switch mount locations are adjustable. Note orientation of the micro-switch retainers so that the link arm clears.



Deck lid Limit Switch assembly. One micro-switch tells the system that the lid is up, the other when lid is down. A lever mounted to the Deck lid cylinder arm is the activation. These are also adjustable.


Main Switch and 40A Circuit Breaker


Deck lid Safety switch. This ensures the hydraulic system valve operation will not function unless the Deck lid is unlatched and slightly raised.


Trunk Lid Safety Switch. This ensures the hydraulic system valve operation will not function unless the trunk is closed.