<VV> I Hate Headlight Switches

[Tim Verthein]

Ja'ever have one of those days..when something so simple..takes
forever?
Thought I'd replace the headlight switch in my 64 Monza with a Spyder
dash.
Ordered a switch along with many other items from one of the major
vendors.
I only wanted to replace the switch because I had to pull it out hard
against the stop to get the lights on..and if I didn't pull hard enough
they'd go out when I hit a bump.  And as long as I was ordering
parts...i had 'em toss one in. 

So...removing the old switch was a piece o' cake.  Push secret button,
pull knob out. Unscrew nut.  Pull plug.  Ta-Dah.  Plugged the plug into
the new switch, and discovered that there was simply NO way it was
going to fit.  Near as I could tell (without x-ray vision) the new
switch had a wider metal base plate that protruded about 1/4 inch or so
either side, making it hit the tach housing and the left edge of the
dash on the other side.  Out came the dremel.  I trimmed off the metal
base plate just about flush with the switch itself.  The stupid thing
was....the metal base has a lip around it that gives the bottom of the
switch, and the front piece where the nut goes, structural rigidity. 
With out it, the switch became somewhat flimsy.  But..it fit.  I put it
in.  Worked great.  But was not "solid" .  Fearing this would cause
evil problems down the road, I decided to clean the contacts in the
original switch and put it back in while I searched out a better
replacement. 

I head out for work at 5 AM, in the dark, and find out I now have no
dash lights. I decide after work to visit my FLAPS, where upon I find
they actually HAVE a '64 Corvair headlight switch in stock! I buy it. 
The base part is considerably narrower than the one from the vendor,
but bigger than the original.  I remove the original that I had put
back in, discovering I smucked a terminal putting it back in, hence no
dash lights. New one plugged right in, still didn't really want to
fit..it was a very tight squeeze but I managed to get it to line up and
get the nut in, and all seems to be just fine.  Everything works, and
it's not flimsy and I didn't have to make any mods. But it's still not
exactly right.  One side of the switch is forced up against it's side.

Moral of the story. Don't dremel a switch. And..they're definitly NOT
physically all the same.  I imagine the switch from the vendor would
fit any non-Spyder dash 64..no tach housing to get in the way.  But
holy cripe did something simple turn into a two day pain in the butt!

The switch from my FLAPS is from Standard Motor Products "Tru-Tech"
made in, of all places, India!  I don't know where the vendor switch
was from, as it came in their own parts bag and no country of origin is
on it.  I would say, side by side, that the vendor switch may indeed be
of higher quality...maybe...but if I can't make it fit..that dosen't
help.

Anyone else have this trouble? Or know of a more exact replacement?  I
hate it when something simple gets out of control!

Tim in Bovey

===
You *can* repair a flip-flop with a capacitor!
===

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