1956 Headlight Switch

[Richard M.]

Re: 1956 Headlight Switch

That one I fixed had zero corrosion. Just loose rivets, probably loose when it was made.

That's a fine test fixture. Did you ever do any experiments with the reproduction '58 to '63 HL switches? I think their circuit breaker spec is far from what it should be. The last one I used made the headlights flicker like a Christmas tree. I ripped it out, disassembled cleaned up a original and used that.

Rich

[Dan D.]

Re: 1956 Headlight Switch

Rich,

Have not had the opportunity to test any repo switches. But there is plenty of documented information on this site and others that these switches (56 and up) have serious circuit breaker problems. Corvette Central for one has admitted that they do not test these switches. I do not know if they have corrected this problem or not, as I have not seen any response from them. But these switches have caused several of our members much heartache and stress as this is a safety issue.

If someone would like to send me a repo switch I would be more than happy to test it for them at no charge (shipping charge only). I know what the interrupt current should be for these switches, and for sure the repos interrupt at lower current - lower than what the headlights draw. I'm not sure if these breakers can be 'adjusted' or not. Generally - it is no. You cannot adjust the pre-load on the bi-metal strip by bending it, and not sure if there is another way to increase tension.

If anyone has these switches, I would not use them and they should be returned for credit. I had one experience of headlight failure while driving (not a corvette) and while I managed to get the car safely shut down, I can tell you it was a very stressful event.

-Dan-

[Richard M.]

Re: 1956 Headlight Switch

Dan, email me your address and I have one here I'll send you Fedex with a Fedex return label.

This would be a great test so we can "fix" another vendor problem.

Thanks,
Rich

[Richard M.]

Re: 1956 Headlight Switch

I rebuilt a 072 switch. There was extensive corrosion on the copper rivet at the rheostat. I repaired it after removing and salvaging the rivet and was able to swedge it back on after cleaning and silver soldered it to the removable lug.

Photobucket Photos of the 072 I repaired, another 072 with a bad rheostat, and a 082/090 switch. The differences are obvious. The fuse in fact is a "AGA 3". THe 072 I repaired now works perfectly.

http://s684.photobucket.com/user/richmz/library/Misc/1956_1957_CorvetteHeadlightSwitches

[Richard H.]

Re: 1956 Headlight Switch

Rich, do you know if there have been any improvements to the repro switches in the past couple of years? I recently bought one for my '57 project, as it had a switch from some other vehicle with it. After reading this thread I'm a little concerned about using a repro switch.

[Richard M.]

Re: 1956 Headlight Switch

Rich, do you know if there have been any improvements to the repro switches in the past couple of years? I recently bought one for my '57 project, as it had a switch from some other vehicle with it. After reading this thread I'm a little concerned about using a repro switch.

Richard, I haven't tried the repros for 56/57, but I can tell you that the repro 58-62 switch has given me fits in the past, with intermittent operation due to the circuit breaker being out of spec.

I sent one repro to Dan for testing and that particular one had good results. I'm unsure if they corrected the circuit breaker flaw on that one.....or if it was simply pure luck.

Rich

[Dan D.]

Re: 1956 Headlight Switch

I'm not sure if they have corrected the circuit breaker problem or not. That being said, I have a test set-up that will test the entire switch, including the CB. It is pictured in an earlier post on this thread.

If you want, I can test this for you, then we will all have a better prospective if this problem has been corrected by the supplier(s). E-mail or PM me if you want to (no charge).

Rich, interesting how you repaired the rivet and still re-used it. What I generally do with the rivet is wire brush it, flood it with rosin, and solder it. It is still difficult to get the solder to flow, as the corrosion extends inside the rivet. But enough heat and several attempts will usually burn through the corrosion and you can get good solder flow around the rivet. This cannot be seen from inside the car, and it will never corrode up or fail again. Or you can use a small screw instead of the rivet. That too will work.

-Dan-

[Richard M.]

Re: 1956 Headlight Switch

Dan, I used a small piece of flat brass and used it as a shim between the rivet and the wire, then used fine solder and filled it along the inside and then with a bead of silver solder at the peened end.

Rich

[Richard H.]

Re: 1956 Headlight Switch

Well, the good news is I found an NOS 082 switch on ebay for a relatively reasonable price. Dan, I will see if Keen Parts will take the repro switch back, as it never had any current put to it. If not, I will send it to you for testing. At this point, is it unknown if the '56-'57 repros are defective like the '58-'63s seem to be?

Thanks- Rich

[Dan D.]

Re: 1956 Headlight Switch

Rich M. Sounds like a good repair. Don't think that will ever fail again, but the rivets are a known weak point on old switches because of the dissimilar metals.

Rich H. I would think you should be able to return the switch okay, but sometimes suppliers don't like to honor electrical items. Your NOS switch should be free of corrosion, but look it over real good anyhow. After all, it is 60 years old.

-Dan-