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DW Horton, with his Daughter Lily

Part 23
Headlight Wiring

This is what I was making when I discovered that the tire was a great bending die for a large radius.

art23a
art23b

You can see a very slight bend on the horizontal section of tube. Basically, I wanted to give it some shape so it wasn't straight.

The little stainless piece in the back of the headlight is a piece from the Parr headlight conduit kit. It comes with some braided hose, and two of each frame fittings and headlight fittings. I machined a shoulder on the headlight fittings and drilled them 3/8" all the way through. There are six wires in a '32 headlight with turn signals, which *just* won't fit in a 3/8" tube. I took the ground from the turn signal and bolted it to the inside of the light, which is bolted to the frame. Five wires fit very snugly inside the tube, but they do fit.

Part 24
Booster or No Booster?

art24ab

Booster or No Booster?
If you can't decide whether to run power brakes or not, or if you just want to experiment like we did, just run braided lines to the master clinder from the frame. It's a heck of a lot easier to lower the master cylinder - you don't have to open the system to check levels. Just unbolt the master and presto wammo, your cylinder is as free as a duck without a leg tag.

Part 25
Brake Pedal Return Spring

We spent a lot of time thinking about how to put a return spring on the pedal. We liked the idea of having a spring because it would give the pedal a more 'solid' feel, and we could effectively adjust the pedal pressure. I liked the way Cam did the return spring on his '32 and, since imitation is the highest form of flattery, I had to do one like it. Cam made his with a split ring with a set screw that tightens the spring plate to the bar. I decided to use a separate piece with two set screws, mostly because it was easier to make. I could also adjust the tension easier, because when I turn the rod it's not trying to turn the spring as well.

art25a

art25b

I machined the piece with the set screws from mild steel, and the spring plate from aluminum. I imagined that I'd be able to tighten the set screws tighter in steel. The shoulder on the left side in the picture is for my brake light switch which I mounted underneath the master cylinder bracket. The shoulder on the right side is to hold the spring.

When I push on the brake pedal, the aluminum plate comes away from the brake light switch, thus turning on the lights. I also shortened the 3/8" plunger rod and welded it to the end of the bar. It's just a bit cleaner, since the bar goes right to the plunger.

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