Fusible Links

[Chuck G.]

Re: Fusible Links

Hello Bill; Do you know of a source for the black "butt splice" devices used to attach the fusible link sections to the "main" wire ? I've never seen anything like them in various electrical supply stores I have visited. Chuck

[Chuck G.]

Re: Fusible Links

Hello Bill; Do you know of a source for the black "butt splice" devices used to attach the fusible link sections to the "main" wire ? I've never seen anything like them in various electrical supply stores I have visited. Chuck

[Bill Clupper]

Re: Fusible Links

No Chuck, they were not a "device" as such, but a molded-on piece that was molded over the actual aplice itself. Let me explain the process-First the two ends are joined together with as "splice clip" that is formed over both ends and crimped with a press (approx 5-ton press). Then the joint including the clip was "dip soldered" by placing it in a bath of molton solder for a couple of seconds (insert and remove quickly as as not to burn the insulation). Then the assembly was placed in a mold and plastic was molded over the joint, covering the entire clip and both ends of the wires leading into the joint. This process was used from the late '60's until the mid-eighties, and is not reasonably duplicable by the hobbiest. That's why I advocate the use of a "junkyard" sample, splived discretely into the main harness beranch a foot or so upstream of the link where it can be easily hidden. The process was modified slightly through the years, with changes occurring in bolt cable insulation and cable color. The closer the "doner" is to the actual yaer of the Corvette being restored, the better the match. The process only vaguely resembles the configuration used today which involves heat-shrink tubing and a sealant.

[Bill Clupper]

Re: Fusible Links

No Chuck, they were not a "device" as such, but a molded-on piece that was molded over the actual aplice itself. Let me explain the process-First the two ends are joined together with as "splice clip" that is formed over both ends and crimped with a press (approx 5-ton press). Then the joint including the clip was "dip soldered" by placing it in a bath of molton solder for a couple of seconds (insert and remove quickly as as not to burn the insulation). Then the assembly was placed in a mold and plastic was molded over the joint, covering the entire clip and both ends of the wires leading into the joint. This process was used from the late '60's until the mid-eighties, and is not reasonably duplicable by the hobbiest. That's why I advocate the use of a "junkyard" sample, splived discretely into the main harness beranch a foot or so upstream of the link where it can be easily hidden. The process was modified slightly through the years, with changes occurring in bolt cable insulation and cable color. The closer the "doner" is to the actual yaer of the Corvette being restored, the better the match. The process only vaguely resembles the configuration used today which involves heat-shrink tubing and a sealant.

[Chuck G.]

Re: Fusible Links

Thanks Bill, that explains it. It certainly looked like these devices were molded into/onto the wiring, and not a simple "butt splice" type connector. I'll make a junk yard run in the fall or winter when the wild roses and other "sticker bushes" have died down. Thanks again. Chuck

[Chuck G.]

Re: Fusible Links

Thanks Bill, that explains it. It certainly looked like these devices were molded into/onto the wiring, and not a simple "butt splice" type connector. I'll make a junk yard run in the fall or winter when the wild roses and other "sticker bushes" have died down. Thanks again. Chuck

[Jack H.]

Glad you agree!

While you appear to disagree with advice I gave, looks like you actually agree with my points:

(1) Some original FL's were NOT hidden inside harness wrap. (2) Some are 'pregnant snake' assys. (3) Original replacements can be found at scrap yards off Chevy

passenger cars of the era to maintain factory authenticity

at reasonable cost. (4) They were colored (black is a color).

Appreciate the inside construction skinny! Never dissected one and your super post saves me the action. Thanks, Bill....

[Jack H.]

Glad you agree!

While you appear to disagree with advice I gave, looks like you actually agree with my points:

(1) Some original FL's were NOT hidden inside harness wrap. (2) Some are 'pregnant snake' assys. (3) Original replacements can be found at scrap yards off Chevy

passenger cars of the era to maintain factory authenticity

at reasonable cost. (4) They were colored (black is a color).

Appreciate the inside construction skinny! Never dissected one and your super post saves me the action. Thanks, Bill....