Under dash insulation-HOW

[Harvie C.]

I'm trying to install the under dash insulation with the rubber plug retainers on my 65, but with no success. Does anyone know how to install these rubber retainers? Thanks for your help.
Harvie

[Larry M.]

Re: Under dash insulation-HOW

Harvie:

There was a RESTORER article on this five or so years back. EDIT: Article was in the Fall 2002 RESTORER, Volume 29-2. It has also been discussed a few times on either this forum or "the other forum".

Basically you either make or buy a special tool that will help to push through the rubber retainer. The RESTORER article showed a picture of this. Long Island Corvette (and possibly others) also sell a similar tool.

Then you get a helper and also use a wire or string on the tip of the rubber retainer and thread it through the insulation and firewall hole. Then lube the retainer and both "push" and "pull" (helper) the retainer into place.

If you get lucky, you MAY be successful doing it yourself using the pusher tool. But don't count on it.

EDIT: John Hinckley also provided a follow-up article that described how the St. Louis guys did it on the factory floor. I do not have this RESTORER Volume Number handy, but it was obviously a later edition.

Larry

[Rich P.]

Re: Under dash insulation-HOW

Harvie,

first get a 3/8-16 bolt about 2-1/2" long fully threaded (no shoulder) and a nut. Then you'll need 2 large fender washers (large outside diamiter with a 3/8" inside diamiter). Now cut out 2 pieces of plastic the same size as the metal washers (an old gallon milk container will work) Now put the bolt through the hole for the plug with a washer and plastic washer on each sied (plastic on the firewall and insulation) and tighten down to compress the insulation. Don't be afraid to really crank just make sure it is not ripping the fiber board backing. Once the material is fully squished you can remove the bolt.
Now to install the plug. They make a tool that aids in this if you look on the Long Island Corvette Supply site. You put the plug on the tool and grease the tip of the plug as well as the inside of the hole and insert, it is best to move the tip of the plug around as this is done. If you still have problems as you are doing this it may be necessary to file the hole in the firewall open just a bit.
Also it is not necessary to buy the instillation tool, it could easily be made at home.

Hope this helps.
Rich

[John H.]

Re: Under dash insulation-HOW

Harvie-

In the plant, we kept the rubber plugs in a bench-top tray under a heat lamp, and dipped them in a 50-50 solution of Joy soap and water just before installing them. The guy on the inside used the tool, and the guy on the outside grabbed the end of the plug with duckbill pliers and pulled it while the inside guy was pushing.

[Harvie C.]

Re: Under dash insulation-HOW

Rich and Larry,
Thanks for the quick response and the information. I've got a friend coming over this afternoon to try and get this done. Again thanks for your help.
Harvie

[Alan S.]

Re: Under dash insulation-HOW

Hi Rich,
I remember the hints about the tool, helper, and grease/Joy, but compressing the the insulation is new for me. THANKS!
Regards,
Alan

[Rich P.]

Re: Under dash insulation-HOW

Harvie and Alan,

Your welcome.

Here is my trusty under dash installation kit. I use this on all GM insulations I do. The compressing of the insulation has turned this from one of my most dreaded chores on a restoration to a pleasure.

Rich

[Peter J.]

Re: Under dash insulation-HOW

I found this tool done by somebody on another board. It makes up for the short commings of the tool I bought and the one I made. This guy is pretty smart

[John H.]

Re: Under dash insulation-HOW

The tool we used in the plant was similar, made from a #2 phillips screwdriver with the end rounded off and a washer brazed to the shank; that space between the head of the plug and the washer allows the plug to be stretched slightly at installation, reducing the diameter of the plug's shank for less effort, but limiting the plug's stretch so it doesn't separate.

[Stephen L.]

Re: Under dash insulation-HOW

i installed the plugs with soapy water and a nylon string around the pointed end. Pulled the string thru the hole while pushing from the dash side. (2 people job). Worked for me. Tried the blunt screwdriver routine and succeeded in poking holes in the plugs....

[Harvie C.]

Re: Under dash insulation-HOW

Everyone, thanks for all your suggestions. My friend came by this afternoon and we got them on. It didn't take much time at all. We pulled with the string on one side and pushed on the other. Had to work with them to get them all the way through, but it's done.
Harvie