Date: Sun, 1 Nov 2015 15:36:47 +0000
Reply-To: Jim Felder <jim.felder@GMAIL.COM>
Sender: Vanagon Mailing List <vanagon@gerry.vanagon.com>
From: Jim Felder <jim.felder@GMAIL.COM>
Subject: Felder Industries dash foil workaround--one solution to fix iffy
instrument lights
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Yesterday I had the time to make a long-needed foil swap in my 83 diesel
instrument cluster. I had to solder a small piece of braided copper to
jumper a bad spot on the new foil, no problems there.
I inspected the donor foil and it looked good. When I installed it,
everything worked except the instrument lights. Sick and tired of having
some light or another out, I tested and found that none of the three
instrument cluster lights were getting an juice.
I went to a parts store and bought three of the smallest bulbs I could find
that I could actually see and get to the terminal wires by unfolding them
off the back. The bulb was a number 24. I also got a set of alligator clips
to cannibalize for wire as guess what, the red and black wired clips were
cheaper and smaller in diameter than any other wire they had. I got an
automotive connector as well. Any old kind will do. LED bulbs would have
been better but they didn't have them, that will be a future upgrade.
I started with the harness for the bulbs. After soldering red and black
wires to each, I went to the instrument panel and inserted each into its
respective hole to make sure all were long enough but not too long. I
picked a spot and cut the bundle where I would solder the harness wires to
the three lights to the power source. For convenience, I just used a spare
spade terminal I left for future gauges when I installed my EGT and boost
gauge. It isn't on the dimmer circuit, but next time I actually pull the
cluster I will probably change it over.
The most difficult part was figuring out a way to fasten the bulbs in their
place without the twist-in socket. I got an inspiration from my soldering
iron which has a cork handle. I cut strips out of 1/8 inch cork gasket and
put a hole in the center of each piece (you see how large and where the
holes go when you take the small fixtures out) that fit the bulbs snugly. I
made the holes with a harbor freight leather punch. I added two holes in
the cork to push down over the plastic pins that position the foil on the
fixtures. So, the cork strips push down over the pins and the lights push
into the holes in the center of both outers ones, holding everything in
place. I simply glued the middle on over the idiot light indicators with a
few drops of superglue. If I ever get this foil working, or get a working
foil, I can simply pull this stuff off and go back to the original setup.
No damage was done nor modifications made.
I chose cork because automotive gasket material is meant to resist high
temperatures and I did not know how hot the bulbs get. I still don't know
that and will have to keep an eye on this over the nest few days as I would
hate to be on the road and smell plastic melting. I don't think that will
happen, but I am prepared to either reduce the current to these or go to
cooler bulbs.
They look good and are really bright.
Jim