Cigarette Lighter Fuse Holder for 1963 to 1966 Corvettes - No harness modifications

[Gary B.]

Re: Cigarette Lighter Fuse Holder for 1963 to 1966 Corvettes - No harness modificatio

Rich,

A big thanks to you, and to Dave Z., for another service to the members.

Gary

[Richard M.]

Re: Cigarette Lighter Fuse Holder for 1963 to 1966 Corvettes - No harness modificatio

Attached below is Dave's 2nd revision of the PDF document he's converted from the html here in the thread. Putting it here for comments before we finish it and I put it up in the DoRD Sticky. And..... Wow, as usual, Dave's conversion work and editing is superb. I love the way he takes my on-the-bench/on-the-fly hen scratchings and pretties them up too!

I have a few more ideas and may come up with a version 3 and 4 when I get all of my parts in for more prototyping.

V3 may be a combination of V1 & V2 with "Y" pigtails on the ends of the fuse adapter wires to allow usage for both original AND repro C2 lighters. Not sure yet, as I'm concerned about the unused ends flopping around and shorting out, so I'd have to come with insulators too. Just 'thinkin about it.

V4 would be a C1(53-62) version with flat blade terminal ends with the plastic housings to mate with stock harness clips. I just ordered some of those parts too.

Eventually I'd like us to submit it to Vinnie for a future Restorer article. Again, I'm wanting to share all of this info to all members so they could make them themselves.

Rich

[Thomas B.]

Re: Cigarette Lighter Fuse Holder for 1963 to 1966 Corvettes - No harness modificatio



https://tech.corvettecentral.com/2008/03/c1-and-c2-corvette-cigarette-lighter-alert/

[Gary B.]

Re: Cigarette Lighter Fuse Holder for 1963 to 1966 Corvettes - No harness modificatio

Thomas,


There are two separate issues that are involved. The Corvette Central warning is talking about the presence of a bi-metallic element to the back side of some lighter housings. In a 2010 posting on the Corvette Forum John Hinckley described that bimetal element:





However, the Corvette lighter feed circuit wasn't fused until 1967; if you have one of these later housings in a pre-'67 Corvette and overload it, you'll fry the dash harness when the U-shaped bi-metallic element dead-shorts the red feed wire to ground.







IMG_9888.jpg





Gary

[Terry M.]

Re: Cigarette Lighter Fuse Holder for 1963 to 1966 Corvettes - No harness modificatio

I believe the danger to the harness is only when the lighter in use and power is being drawn through it. Is it correct to assume that if you don’t use the lighter there is no danger? Also, I found this tech article on Corvette Central and am wondering if their solution makes any sense. Thanks

https://tech.corvettecentral.com/2008/03/c1-and-c2-corvette-cigarette-lighter-alert/

Thomas
There is a risk of a short in the red (positive) wire in pre 1967 Corvettes if that wire is not fused and if that wire is damaged either in the engine compartment or under the dash and it shorts to ground. In 1967 Corvettes that red wire is protected under the dash, but not in the engine compartment. In C3 Corvettes that red wire is protected by a fusible link at the starter, where that wire begins, and under the dash with a fuse. In 1988 and older Corvettes there is no protection for that wire.

In the event that wire is damaged and shorts to ground either in the engine compartment or under the das it will damage the involved harness and could ingenerate the car. We all probably have seen the results of a fire in a fiberglass car. That is not a pleasant picture.

The current judging bonus points for a battery cut off switch and a fire extinguisher are the result of an incident at the 1992 National Convention in Warren Michigan in which a 1969 Corvette began to have smoke coming from the engine compartment due to an electrical mishap. Fortunately, the owner was nearby and disconnected the battery before any serious damage took place, but the result is the encouragement to have remedial items in place.

Having protection (as in a fuse of some type) for all of that wire in 1966 and older Corvettes should be regarded as a safety item and ignored (if neatly installed) in judging in my opinion.

I have spent the last 20 years of my career in the electric utility business involved in the repair and replacement of underground cables, admittedly at a much higher voltage then 12 volts. Many electrical outages are due to damage or failure of these underground cables. The underground cables used in our industry have an average life span of 30 years. I doubt the wires used in Corvettes of any year are intended to last longer than that. Protect your Corvette's electrical system - as much of it as you can.

[Thomas B.]

[Gary B.]

Re: Cigarette Lighter Fuse Holder for 1963 to 1966 Corvettes - No harness modificatio

For 63-66, the power windows also work with the ignition switch in the Off position. Among other reasons, GM wanted to make it easy for the owner to smoke with the windows down without ever getting the key out of his pocket.

Gary

[Richard M.]

Re: Cigarette Lighter Fuse Holder for 1963 to 1966 Corvettes - No harness modificatio

Fred, Only the 2 prong reproduction has the bimetal strip so it's ok.

Rich
P.S. 1953 to 1967 lighters, and 1956 to 1966 power windows worked Key = OFF. 1967 PW needed Key = RUN. (See This Thread for info)

[Thomas B.]

Re: Cigarette Lighter Fuse Holder for 1963 to 1966 Corvettes - No harness modificatio

Richard,
Looks like I can buy a barrel clip but where can I get the plastic housing for the clip?

Tom

[Richard M.]

Re: Cigarette Lighter Fuse Holder for 1963 to 1966 Corvettes - No harness modificatio

Richard,
Looks like I can buy a barrel clip but where can I get the plastic housing for the clip?

Tom

Tom I looked everywhere but no joy. LL & M&H must have their own made in house or a secret supplier.

I'm going to use 2 layers of heat shrink with a hole punched for the pin.

[Richard M.]

Re: Cigarette Lighter Fuse Holder for 1963 to 1966 Corvettes - No harness modificatio

So I received the special clips for the barrel pin yesterday. I took a chance and it paid off.

Here they are. The fit is perfect.

That Ebay listing before I bought them, showed the manufacturer as Auveco, but I could not find these terminals on their website, which is very cumbersome to use. You'll see.

Go to...Products...Electrical...Terminals....Solderle ss Terminals.... yields 341 items. The other night I gave up and placed the order for the 10 pcs on Ebay.

I then did a search yesterday on their site using the part# on the box....bingo. However I'm not sure how to order direct. There's no method to create a Account that I could see. May need to be a distributor. I'll likely give a call when I get time.

Auveco Part # 23167

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[Richard M.]

Re: Cigarette Lighter Fuse Holder for 1963 to 1966 Corvettes - No harness modificatio

I did some current measurement testing of the lighter. I had a reproduction C2 element new in the box. After a few t w e a k s of the 3 prongs and holder prongs, it took about 20-25 seconds to pop out and glow red from cold.

I used my HD battery charger so I could vary voltage.

Test Results:
At 12.6 v, simulating a fully charged battery, ignition OFF, at rest => ~4.0 Amps

At 13.7 v, simulating ignition ON, running driving, alternator charging => ~4.4 Amps

Just verifying that a 15 Amp fuse is totally adequate for the 63-66 lighter circuit. I may do some testing with cell phone chargers later. Any other suggestions? If I have something else here I could try it.

Rich

[Frederick H.]

Re: Cigarette Lighter Fuse Holder for 1963 to 1966 Corvettes - No harness modificatio

Rich, found the 23167's on Amazon for a pack of 25 and ordered them. I can send you some extras if you need 'em.

[Gary B.]

Re: Cigarette Lighter Fuse Holder for 1963 to 1966 Corvettes - No harness modificatio

Either a Dustbuster that plugs into the lighter socket or a 12V tire air pump, if you have either of those sitting around.

Gary

[Richard M.]

Re: Cigarette Lighter Fuse Holder for 1963 to 1966 Corvettes - No harness modificatio

Either a Dustbuster that plugs into the lighter socket or a 12V tire air pump, if you have either of those sitting around.

Gary

Gary, great ideas. I forgot I have a 12v mini vac and two 12v air pumps. I'll try them.

I also have my 12v car jack with its lighter socket, but I always use the supplied battery alligator clips on it. It has it's own fuse integrated into the lighter plug. I'll have to check its rating. Edit... 6 Amps.

Rich