Rich Mozetta - or anyone - help with interior install sequence

[Donald H.]

I will be getting my 66 coupe back from paint next week. I've been thinking about the best sequence for installing all the stuff in and around the dash.

As I recall when I took it apart (no I didn't take enough pictures), the wiring harness goes above all the other stuff, e.g. pedal assembly and park brake handle assembly, so I need to string the harness across under dash before these go in.

Any advice on the following sequence from experience appreciated.

Dash pads
Wiring harness
Gauge cluster (suspended with long 1/4-20 bolts to aid wiring to harness)
Steering column
Hood release
Pedal assembly
Park brake handle assembly (with V74 flasher)
Speaker grille
Speaker
Radio
Radio side panels with antenna switch
Glove box
Shifter surround/console

Thanks,

[Bob R.]

Re: Rich Mozetta - or anyone - help with interior install sequence

You mentioned the dash pads but didn't say if the fiberglass center section is still in the car. I would install the pedal assembly first, then attached the speaker grill, speaker, defrost duct and dash pads to the fiberglass and install as a unit. Install the cluster with the steering column out make sure the bulbs are all working before you move to install anything else then wire connections then the emergency brake handle and and the oil gauge. Steering column and glove box go last. You may want to install a connector on the glove box light wire so it can be disconnected and connected easily and you may want to install a fuse on the cigarette lighter wire while it's accessible for safety reasons.

[Donald H.]

Re: Rich Mozetta - or anyone - help with interior install sequence

The fiberglass dash is already in the car.

Thanks

[Bob R.]

Re: Rich Mozetta - or anyone - help with interior install sequence

If the center section is in the car you will have to install the dash pads with as much room as you can so I would start with them, then the radio speaker and grill and defrost duct, heating controls, radio, heat duct. You still want to finish with the steering column, glove box, and console trim last items.

[Donald H.]

Re: Rich Mozetta - or anyone - help with interior install sequence

The fiberglass dash is already in the car.

Thanks

[Richard M.]

Re: Rich Mozetta - or anyone - help with interior install sequence

Don,

This is the order I use....

Firewall insulation in yet? Dash pads after that. Either way works though.

If the heater box is not in yet best do that as early as possible, along with control cables to the center ash. Radio early too, even before the heater box is easier. Also, if any plans to rebuild/reseal the kick panel vents, it'll be easier on your body to do that early too. As Bob said, pads. speaker grille & speaker(don't forget, transformer towards Pass side), etc. Also, if your wiper motor and arms are not in yet, do that before anything else. Do a quick manual test of the arm orientation before the motor goes on. It's common to reverse the 2 transmissions levers on the arms. Also don't forget the little anti-squeak rubber washer between the arms at the motor shaft.

Next can be the pedal box but you may have to trim the insulation at the top area of the pedal box mount flanges if it's reproduction. Both pedals must be attached as a assembly before the whole thing goes in, but don't attach clutch rod or brake master cylinder yet so the pedals will lay on the floor out of the way. Put the rubber pads on the pedals so you don't cut your head later on the sharp metal. The flanges of the pedal box must lay flat on the firewall, not on top of the insulation. You may have to work it in there a bit.

I wire the harness to the cluster on the bench and I connect power to it to thoroughly test most functions and lamps. Below is a test procedure that Dave Z and Tim W created that can help. Also, as Bob mentioned, best to add a inline fuse for the lighter for safety, just make it removable for the judging aspect if expected.

I lay the harness/fuse panel over the z-bar and use my 5 long 1/4-20 bolts to hold the cluster in position while fishing wires. I use a fish wire for the door courtesy light switch wires. Before fuse panel attachment, don't install the insulation rubber fastener plug just below the fuse panel until after the floor dimmer switch harness extension is fished down behind the insulation to the floor area for the dimmer. Plug the 3 prong connector to the dimmer before attaching it to the floor. Tight spot down there.

After cluster, then headlight roll switch. I use a little dum-dum to hold the flat nuts. Switch tabs "above" the cluster lip, not below. Then park brake and V74 flasher, Hood release. I leave the kick vent cables off and tucked behind the pedals and do that last. They get in the way later.

When everything else is in, the steering column can go in. Don't forget the trip odometer cable. In the engine bay, make sure the rag joint is centered on the steering box shaft. I usually mount the upper joint flange to the end of the column shaft once it's passed through the firewall, seal, then cover plate. Ensure the upper end shaft telltale notch is facing the sky. I then mate the upper half to the rag half then attach the 2 lockwashers and nuts and torque to spec.

Radio side panels, carpet, then shifter console plate. Glovebox is last.

Rich
edit......Links to cluster bench test docs here.....

http://www.corvetteforum.com/forums/attachments/c1-and-c2-corvettes/47983162d1463675608-two-pdf-documents-on-wiring-and-bench-testing-the-instrument-cluster-and-dash-wiring-and-bench-testing-the-mid-year-corvette-instrument-cluster-zuberer-and-welsh-rev-5-19-2.pdf

http://www.corvetteforum.com/forums/attachments/c1-and-c2-corvettes/47983163d1463675608-two-pdf-documents-on-wiring-and-bench-testing-the-instrument-cluster-and-dash-mid-year-corvette-non-cluster-dash-connections-zuberer-welsh-5-19-16-final-mod.pdf

[Joe R.]

Re: Rich Mozetta - or anyone - help with interior install sequence

Rich,

More great info!!! Maybe you should write a book in your "spare" time.

Joe

[Donald H.]

Re: Rich Mozetta - or anyone - help with interior install sequence

Rich,

Thanks very much. Your are a resource treasure.

One question - Do you leave the harness connected to the cluster and install the cluster and harness together?

I've been testing what I can, but the documents you provided make that straight forward now. I want to be sure and test my hazard flasher. I bought it off Ebay and the wiring connectors had been cut off, so I had to figure out how to wire the half moon connectors. I used pictures of a completed assembly that I found on Ebay and info from another forum member. The picture on the left is what I started with and the finished on the right. I was concerned about frying something, so I will interconnect it with a fuse on the positive side of the power feed as you suggested.

Thanks again,

[Donald H.]

Re: Rich Mozetta - or anyone - help with interior install sequence

By the way,

I had installed the heater box (inside and out) before I dropped the body back on the chassis. Also, the firewall insulation is already installed.

Just to make sure I am clear, Before you install the cluster/harness, you install the pedal box, speaker grille and speaker.

Thanks,

[Richard M.]

Re: Rich Mozetta - or anyone - help with interior install sequence

Joe, Maybe when I retire. ps I haven't forgotten the column write-up. I'll get to it soon.

Don, Yes, I connect the harness to the cluster together first, then the assembled unit into the car. It's easier to do that, and that's how it was done at St Louis.

The pedal box goes is before the cluster to make for easier body contortions. It can go in later though. Just harder on the head and neck. I put the speaker/grille/radio before all of that.

If you followed the V74 flasher switch assembly wire colors you should be all set. I have one here if you need confirmation. Keep in mind the orange wire plugs directly into the fuse panel hot wired unfused terminal. I'm not sure if the switch itself is fuse or circuit breaker protected. I haven't opened one up to check.

Rich

[Donald H.]

Re: Rich Mozetta - or anyone - help with interior install sequence

Rich,

Do you possibly have a good picture of the back of a cluster with the wiring all attached. I've got mine together and tested per the Zuberer/Welch doc and it all seems to work. My problem is attaching the harness with the pins that push into the cluster housing. I can't seem to bend it around to clear the E-Brake and Headlight bulb housings.

Thanks,

Don

[Richard M.]

Re: Rich Mozetta - or anyone - help with interior install sequence

Yes, the harness is very stiff there when the pins are locked in. That's probably why they're typically not attached on most cars that have had cluster work done.

I had to work at that area for a while. I tried to get it so it rested above the 2 lamp sockets, but would have a tendency to knock them out. I think it ended up resting against the top of both of them, which helps keep them there. Get it the best you can as that's all there is.



It's not the ideal design. Even original harnesses are very tight there.

[Donald H.]

Re: Rich Mozetta - or anyone - help with interior install sequence

As always, great pictures.

The harness is a Lectric Limited set that a previous owner had installed. The two white push in pins are to close together to get both back in the holes in the cluster housing. I think I'm going to figure out how to rig a retained to the holes that will allow me to use zip ties to pull the harness close to the housing and hold it in place.



Thanks,
Don

[Paul J.]

Re: Rich Mozetta - or anyone - help with interior install sequence

Don,

I think Rich and Bob laid it out pretty well. As a general rule of thumb, put the stuff that is furthest away from you in first (like the speaker grill, etc.)

Once you get into it the map will sort of appear.

Paul

[Donald H.]

Re: Rich Mozetta - or anyone - help with interior install sequence

Thanks Rich,

I attached my steering column and tested the turn signals, worked!

Then I interconnected the hazard flasher (the one I rewired), and it also worked!

I think I'm happy with my cluster and harness so far.

Don