Cigarette Lighter Fuse Holder for 1963 to 1966 Corvettes - No harness modifications

[Richard M.]

I've made a prototype lighter fuse holder for the 1963 to 1966 era. This allows use without modifying the Main harness and can be easily removed for judging if needed. Just don't forget to reinstall it asap to protect the circuit and the car.

These lighters use a special bullet pin terminal for power. Ground comes from the housing mount to the cluster. The main lighter harness clip is a unique design and simply pushes onto the pin terminal.

Here is a typical 3 prong lighter socket and pin terminal.
1967 shown(Orange feed wire from fuse panel Courtesy Lamp fused circuit).
1963 to 1966 similar but the feed wire is Red and is sourced directly from unfused Bat+ power.(see below)
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Here is a 1963 configuration. Note the Red wire. It is unfused and always powered. (Photo courtesy from Fred H's 1963)
Freds_1963_Lighter Connection.jpg

On the lighter socket, the pin is threaded onto the power stud.
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Separate loose parts shown from a different defective(rusted) lighter socket to for reference. The threaded barrel pin terminal is upper left.
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Here is the pin and reference dimensions.
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The harness clip is a special type which may be difficult to acquire. It simply pushes onto the barrel pin and is locked into the pin groove.
1027232030_resized.jpg 1027232031_resized.jpg

Splicing in a fuse to the harness is easiest, but here's another method to fuse the lighter if you don't want to cut the harness. The benefit is if your car is being judged, simply remove the fuse adapter. Unscrew the barrel pin from the adapter, then reinstall it on to the lighter, and connect the standard harness clip back on to the lighter barrel pin.

Here are typical fuse socket assemblies I've had for years. They use blade fuses and are rated 32V @ 20 amps. Round glass fuse holders(upper left) will work as well, but ensure they are rated for at least 20 Amps.
1028230714_resized.jpg

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The barrel pin inner diameter thread and stud is #8-32. I had some brass #8-32 screws in my brass hardware collection. I cut the screw heads off and milled holes in the center using my mill.
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This hole will accept solder for the fuse holder wire on one end. The barrel pin gets unscrewed from the socket then screwed onto the fuse wire end screw.
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The other end of the adapter will screw onto the stud of the lighter socket. I had some 1/4" brass stock(machine screws that I cut the OD threads smoother on my lathe) and drilled and tapped the center 8-32. The end of this will be soldered to the other end of the fuse holder.

This then threads onto the lighter socket stud, from where you removed the barrel pin.
1028230903b_resized.jpg

Here is the completed prototype. I will add some rubberized insulation tubing to each end.
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I use this small butane torch for soldering the wires to the brass couplers I made.
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Here's the completed adapter with details of the ends. I added heat shrink and a rubber insulator at the harness clip end and heat shrink at the lighter housing end.
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The Pre 1963 Corvettes used a flat terminal which screws onto the stud so those fuse adapters are easier to make. The fuse holder will have one male and one female flat blade terminal on each end. Details for C1 fuse points can be found in a PDF document in our Documents Sticky Here.
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C2 left, C1 right.
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====
Rich

[Frederick H.]

Re: Cigarette Lighter Fuse Holder for 1963 to 1966 Corvettes - No harness modificatio

Rich, thanks again for all of your help. Any reason we can't use the blade terminal approach for the C2 lighter?

[Richard M.]

Re: Cigarette Lighter Fuse Holder for 1963 to 1966 Corvettes - No harness modificatio

Rich, thanks again for all of your help. Any reason we can't use the blade terminal approach for the C2 lighter?

Fred, Yes you could at the lighter housing, but you still have the special female connector in the harness made for the bullet pin terminal. You'd have to cut that off and add a female blade type.

Rich

[Frederick H.]

Re: Cigarette Lighter Fuse Holder for 1963 to 1966 Corvettes - No harness modificatio

Got it - thanks Rich.

[Richard M.]

Re: Cigarette Lighter Fuse Holder for 1963 to 1966 Corvettes - No harness modificatio

I'm still on the hunt for available parts to make these easier.

I believe I found the special female harness connector that clips over the lighter barrel pin. Here
It is for 14-16 AWG wiring. 18-20AWG are also available.
It's actually a ford sending unit terminal. It looks just like the GM clip. I need specs though.

female_clip.jpg

I'll try to remove the clip from my harness to compare.
1027232030a_resized.jpg

I've also been looking for a equivalent male pin based on my measurements. I need it to be apx 0.115" diameter and apx 0.280" long, brass or copper, solder or crimp type end.
MalePinSpecs.jpg

I found these which may work. Here

XHF_AC_SL1200crop_.jpg



The diameter is 0.126" so it may work fine.
Edit.. But it's for 12 AWG wire but it'll probably be a good choice.
XHF_MalePinsMod.jpg



Rich

[Richard M.]

Re: Cigarette Lighter Fuse Holder for 1963 to 1966 Corvettes - No harness modificatio

More info regarding the special clip which attaches to the lighter barrel pin.

I wanted a closer look at the stock pin to compare to the one I found earlier and discovered how to remove it from the housing.

There is a very small tab which must be pushed rearward and down.
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Then the housing can be slid back away from the clip.
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It's profile appears identical to the ford sensor clip, except for the 2 side keepers for the blade and the tab found on the GM clip for the housing keeper.
1029230908_resized.jpg female_clip.jpg

[Gary B.]

Re: Cigarette Lighter Fuse Holder for 1963 to 1966 Corvettes - No harness modificatio

Rich,

Great find. And great job.

Gary

[Frederick H.]

Re: Cigarette Lighter Fuse Holder for 1963 to 1966 Corvettes - No harness modificatio

Rich, you are a wealth of information. I do have a problem with our dishwasher if you have some time....

[Gary B.]

Re: Cigarette Lighter Fuse Holder for 1963 to 1966 Corvettes - No harness modificatio

Rich, you are a wealth of information. I do have a problem with our dishwasher if you have some time....

Fred,

So did I. I bought a new dishwasher.

Gary

[Richard M.]

Re: Cigarette Lighter Fuse Holder for 1963 to 1966 Corvettes - No harness modificatio

You guys are too funny.

Coincidentally, our old Maytag DW was working fine forever, but the lower basket wore out and started rusting. I found a replacement basket.....

$285.00 !

So guess what?

For $215 more I got a new Frigidaire on sale with free shipping.

I installed it just last week. Works great and can hardly hear it running too.

So Fred, gimmee a call. I can fix it for you! I'll just send you the info where to buy a new one!

Rich

[Richard M.]

Re: Cigarette Lighter Fuse Holder for 1963 to 1966 Corvettes - No harness modificatio

I've come up with a plan using available off the shelf parts for 2 different C2 versions of the fuse adapter. The reason is twofold. Explanation to follow.

Here are the final prototype versions I've made.

I added additional heat shrink tubing at the barrel pin end to insulate the hex portion of the barrel pin.
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View of coupler ends
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You can create these yourself following my guidelines in Post#1 and acquiring a few parts. The idea here is to make the design available to everyone to make them yourself. It's not that hard if you have a heavy duty soldering gun or small butane torch, solder, heat shrink tubing, simple tools and the necessary soldering skills and to buy a few specialty parts and solder a few wires and brass pieces together then insulate the junctions using heat shrink tubing.

C2 Version 1

This will be specifically for original cars that you plan to have judged with stock wiring and a original 3-prong lighter housing with it's stock threaded contact barrel pin, or for your car with original hardware even if not being judged.

Before and after judging you can have a little less fear of the stock unfused lighter circuit malfunctioning and burning your harness up or the car itself. During judging this adapter will be removed and put aside.

This is what the stock 3 prong housing looks like:
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These are the parts you'll need.

8-32 x 1/2" long brass stud. Here
Stud_min.jpg

8-32 brass coupler. Here
Coupler_min.jpg

Fuse Holder. You can get these at most auto supply stores and can be either blade(several types) or glass fuse types. It is required that the fuse holder rating be 32V and at least 20 amps, and install a 15 to 20 amp fuse for the circuit protection.


Fuse Adapter Installation Instructions:

1- Disconnect battery power from the car.

2- Remove the harness clip attached to the lighter housing contact pin.

3- Using pliers or a small socket driver, unscrew the threaded contact barrel pin from the housing stud.

4- Screw the barrel pin onto the adapter male threaded end. Tighten snugly with pliers if necessary.

5- Screw the fuse adapter assembly female threaded end on to the lighter housing stud. Tighten snugly with pliers if necessary.

6- Plug the fuse adapter barrel pin back into the harness clip. Ensure it is snug.
If not and it appears loose, use small needle nose pliers to lightly squeeze the clip terminal sides together.
Reinsert contact pin.

7- Reconnect power.


C2 Version 2

This will be specifically for cars with a reproduction 2 prong lighter housing with a fixed machined stud contactor. Since you may want your car judged with this non-typical lighter configuration, this fuse protection will also be available for your car. The reproduction housings have been available for years from most suppliers. Note the contactor is not removable and is integrated into the attachment stud.

This is what the NON-stock reproduction 2 prong housing looks like.
1963_1975Lighter.jpg
This version requires a special connector clip at the housing end of the adapter and a special ferrule pin at the harness end. I've explained possible parts candidates previously. I will add this information later when I've finalized where they can be purchased.

Fuse Adapter Installation Instructions:

1- Disconnect battery power from the car.

2- Remove the harness clip attached to the reproduction lighter housing contact pin.

3- Insert the fuse adapter female clip onto the reproduction lighter housing stud.

4- Insert the fuse adapter barrel pin into the harness clip.

5- Reconnect power.


Rich

[Gary B.]

Re: Cigarette Lighter Fuse Holder for 1963 to 1966 Corvettes - No harness modificatio

Rich,

Your solution is a definite keeper. It should go in the Restoration Database section of the Stickies.

Gary

[Frederick H.]

Re: Cigarette Lighter Fuse Holder for 1963 to 1966 Corvettes - No harness modificatio

I agree with Gary; and who would have thought to look at a lamp supply place for some of the materials? Oh yeah, Rich.

[Richard M.]

Re: Cigarette Lighter Fuse Holder for 1963 to 1966 Corvettes - No harness modificatio

Rich,

Your solution is a definite keeper. It should go in the Restoration Database section of the Stickies.

Gary

Yup, I'm going to Ping one of my PDF writer buddies after I'm done to maybe do that!

I agree with Gary; and who would have thought to look at a lamp supply place for some of the materials? Oh yeah, Rich.

Fred, That's funny.... The way you said that, you made me laugh again.

Oh, and btw, it must be ESP..... I just ordered th studs and the coouplers from the brass lamp place.

And also sent a note to the other place asking about the terminal ID spec for the pins. But I jumped the gun and found a few on Ebay I just triggered on.... Here
s-l960.jpg

Now the barrel pins next. They're actually made for capturing stranded wire in a terminal hole but I can make them work too.

Amazon has them.... Argh! I hate Amazon's website. Parse through all of the crap to get the item details. Worse than Ebay by miles.

[Richard M.]

Re: Cigarette Lighter Fuse Holder for 1963 to 1966 Corvettes - No harness modificatio

I just got a email from Dave Zuberer and he created a PDF from the thread for us. I'll review it with him and when it's done I'll add it to our Documents Sticky.

Thanks Dave!

Rich