I bought another car (Page 3/12)
gen2muchwork OCT 19, 08:50 AM
This picture from whenever shous the lights on. It prove that the wiring has been jacked for a while. Both the parking lights and turns are lit.



This is a page from the service manual. It is lies.



I was really annoyed with the brakes and turns. As it turns out the manual was misprinted, or never updated to a newer schematic. Which really threw me for a loop.

This is how it should have been drawn, and how it is wired now.



to put it simply, the contacts in the relay really go from top to bottom:
NC
NO
COM

The manual has it drawn as:
NC
COM
NO

All of of the 12v circuits are now complete, except the horn which is tonights project. along with mounting the charger under the dash where it belongs.

My radio sucks, the power switch does not work right. I'll have to decide if I want to address that while the dash is open. Its an aftermarket "rampage" head unit. It is a post/knob mount radio. I'm not sure if they still make stuff like that. I may just source a period correct replacement from some other manufacturer. There is only mono. 1 speaker in the dash. I'm not even sure modern stereos can output to 1 channel.
Patrick OCT 19, 04:32 PM

quote
Originally posted by gen2muchwork:

miss coal heritage may be a better choice for power vs weight.



That young sprout is certainly much cuter than ol' Miss Dandelion... and she's no doubt also legal age by now.

[This message has been edited by Patrick (edited 10-19-2017).]

gen2muchwork OCT 20, 08:45 AM
Ok, the only thing left on the 12v side is the courtesy light ground. Its riveted on the light and is loose. I fixed the stereo sort of. The power switch on the volume pot was trashed. Since its a single wire unit on switched power, I just bridged the on/off switch and it works, but doesn't really turn off if the key is on. I can live with that for now. Some chrome delco am/fm unit of 77ish vintage would be a nice addition in the future.

I started to install the charger, but for some reason the mount holes dont line up. Maybe I'm missing some adapter. Theres not any info on the mounting of the charger anywhere I can find. There are mounting points, so I'm sure I can whip up something that will adapt and bolt it down. Going to have to be stout though, that charger is heavy. I could see an upgrade to a new style high frequency charger in the future, but the big box with screw in fuses fits the era and looks right. I'm going to close the dash up tonight and snap some pics of my happy dash.

Its still funny that this thing has like 5,000 miles on it. Definitely the lowest of any car I've ever owned.
Tony Kania OCT 21, 08:51 AM
Very cool, and I have been following this.

I have never owned a car with 5,000 or less miles. Had a rotisserie 66 Chevelle, but that was bought with just over that on the odometer.
gen2muchwork OCT 23, 07:41 AM

quote
Originally posted by Tony Kania:

Very cool, and I have been following this.

I have never owned a car with 5,000 or less miles. Had a rotisserie 66 Chevelle, but that was bought with just over that on the odometer.


I was off on that... it's 2397 mi!


I got a lot done this weekend.
The dash is wired and fully functional, the whole 12v and 18v system is.
I also got the charger mounted. As it turns out I have a charger from an early model. The newer ones are a different shape and are not so visible. Really, I like this setup just fine.






I fixed the stereo too. the on off switch on the vol. pot went bad. I'd really like to replace this with a period correct delco of some sort.


Then, I moved on to the contactors. There is a dpst and a dpdt. The contacts are pretty bad. I cleaned them up enough they will work, but I need to decide an alternative in the future. Either source new contacts, repair these ones, or go all electronic controller.








I swapped the worst ones to the reverse circuit. Only about 4 contacts were what I would normally consider useable, but I filed the rest to get some testing and the end of their service life out of them. It's not ideal, but it's all I've got for now. I have to go through some books to reference the contactor parts. I think forklifts use a similar setup, but It may turn out to be very difficult to find the correct ones.
I'm leaning towards a new modern controller. The curtis ebay imitations are pretty cheap. I'd need at least a 500a 48v controller, so it gets $ fast. Perhaps someone will wreck a golf cart on craigslist in the future. The Newer alltrax ones would be right on for what i'd need, but are even bigger $ for good reason.

I also got the drivers door straight. both were so warped that you could fit a hand throught the top with the door latched. Heat gun weight and patience. they should be ok now.
gen2muchwork OCT 23, 12:10 PM
Any chance anyone hear deals with Raymond Forklift parts? I think I found some contactors that match. 110503019 or 800058320 sure look right.
RWDPLZ OCT 26, 07:48 PM
Did they really put those hand-drawn half-assed diagrams in the service manual? Good Gawd. Just bought a copy of the service manual on eBay. I design automotive wiring harnesses for a living, and this is simultaneously intriguing, hysterical, and horrifying. I'll have to show the guys at work once it gets here...
gen2muchwork OCT 27, 07:29 AM
yep, pretty much everything looks hand drawn, and typed with a well used typewriter. It's put together fairly well, but does not cover all of the changes through the years (there were a lot) and warns the reader of this along with wire color discrepancy. There also seems to be a few people who drew them. sometimes they use a dot to denote a connection sometimes not. sometimes they draw a hump over the wires crossing to denote no connection, sometimes not. lol. No matter what its an interesting piece of history and amazing that theis was a "mass produced" car with a manual like this. For a minute, they were the #6 automaker!
As you read it you will laugh when they get to the defroster, going on to explain that the feds required the switch for it, but it's not connected to anything since they had not made a defroster till after #1751, around 1976 and that was an electric element to be glued? on the bottom of the windshield, by the dealer or consumer.

I found some contacts and bought them off ebay, from a raymond forklift. My mail carrier can't read and delivered them somewhere other than my house. I'm bummed out about that. IDK if I will ever see them and they were not cheap. If they never show, I might have to go with a modern golf cart controller.
gen2muchwork OCT 27, 02:58 PM
Hooray honest neighbor



If you are comparing these to the drawing in the service manual, you are right that they don't look the same. The later cars have a slightly different contactor arrangement due to the location. Some were under the seat. Some like this were in the cargo area. The wires point different, and the bridges are different. These appear to fit mine just right.

[This message has been edited by gen2muchwork (edited 10-27-2017).]

gen2muchwork OCT 28, 07:58 AM
Out with old


In with new



I'm lucky they fit! All the contacts and springs are a match,. The ceramics did not all fit the f/r contactor. Since it is a little taller. I just re used my good used ceramics.

[This message has been edited by gen2muchwork (edited 10-30-2017).]