<VV> New Main Harness installation

[Jim McLott]

Stephen,

Please see my answers imbedded in your original question.

>I can see how the main harness cable runs along the heater duct until  
>it reaches the place where it has to cross over just about under the  
>drivers seat (picture on 12-21 and 12-22 of the '65 manual).  The  
>only way it appears that it will be able to cross the top of the  
>heater duct is to remove the plastic duct.  Looking at the Heater and  
>Accessories blowups on page 15-4 of the '65 service manual and  
>reading the instructions for the removal of the rear duct assembly,  
>it appears that I have to remove the duct to under body attaching  
>screw and lower the duct, 

So far, so good.  You have to remove the tunnel covers, of course, and the heater hose that goes from the heater fan housing to the heater duct.  There are three screws that attach the rear of the heater duct to a support bracket and body itself.  Remve these three screws and the the rear of the duct can be lowered enought to slide the duct out. 

>disconnect the clips attaching the control  
>cable along the right side of the duct 

Nope.  The clips attach the control cables to the body, not the duct.  You won't have to fool with the control cables, or the fuel and brake lines either.

>and then pull the duct  
>rearward and away from the front heat duct assembly.
>First, there appears to be no way that the duct will do any sliding  
>rearwards as it buts up against the back wall of the tunnel where the  
>cables exit.  

It will.  You can lower the end and it will slide out.  And while you have the heater duct out, be sure to clean it out with compressed air or your garden hose.

>Second, there is no way to reach into the well that the  
>plastic duct is located in order to disconnect the clips attaching  
>the control cable on the right side to the duct.  The only visible  
>connections are on the drivers (left side) of the tunnel.  If you  
>have ever done this on a '65, please let me know how you did it?
>It also appears that I will then have to bend the clips that hold the  
>wires for the main harness in the tunnel in order to place the new  
>one in the clips and then bent them back in place.  They appear to be  
>pretty stout, and I hope I don't break or mutilate one in the process.

Unless those clips are rusted or have already been bent multiple times, you'll be fine.  Just don't overdo it when prying them open or closed.

>My once beautiful hardtop is starting to look like a parts car.

BTDT.

Also, if you don't have the Assembly Manual for your model year, you should get one.  It shows you things the Chassis Shop Manual doesn't and makes a job like this a lot less daunting.

Happy wrenching!

Jim McLott & Christine, the 1966 Monza convertible wonder-car
Member: CORSA, Corvair Atlanta, Heart of GA Corvairs and Group Red (ret.)
http://www.wittelaw.com/personal/groupred/mclott.htm