A Repair Idea for Broken Headlight Switch Retainers (70-72)

Discussion in 'Interior City' started by Jamie Carnes, Dec 23, 2019.

  1. Jamie Carnes

    Jamie Carnes May the Torque be with you.

    This is something that worked out for me after a little effort. It doesn't look 100% correct, obviously, but we are quickly running out of options since no one reproduces these retainers yet and our cars are nearing 50 years of age. Someone may have a much better solution and, if so, I would love to hear about it.

    I started with the typical broken retainer.
    Photo Dec 22, 12 36 44 PM.jpg

    I ordered a Restoparts headlight switch nut (part #99L0109). These are metal and should be much stronger than the old plastic retainers.
    Photo Dec 22, 12 46 03 PM.jpg

    I gathered a step bit and two burrs (you might be able to use a Dremel tool or the equivalent) and used them in a cordless drill in order to better control the speed.
    Photo Dec 22, 12 37 43 PM.jpg

    I then used the step bit to drill out the hole for the headlight switch pull/push lever. This gets rid of the remaining threads attached to the retainer and allows the Restoparts threads to slip through the hole. I believe I only had to take it to 3/8". After enlarging the hole, I used the burrs to cut away the "shoulders" right above the lowest part of the retainer's face. The burr with the flat top worked well here because I could use the low part of the retainer as a ledge upon which to place the burr. I should have taped the "chrome" surface of the old retainer before beginning this process, as it probably would have prevented some additional scratches I made to the old piece.
    Photo Dec 22, 12 43 16 PM.jpg

    Once this is done, I had to do some cleanup to level and make my new hole as circular as possible. The idea is to come close to counter-sinking the Restoparts nut into the old retainer. Test fit a few times and cut as necessary to get the fit you desire.
    Photo Dec 22, 12 47 33 PM.jpg

    I wire brushed the head of the Restoparts nut before installation just to help it blend in better with the old retainer shell. Again, I know this will not pass a judge's show inspection, but it does help retain the factory look with a stronger part.
    Photo Dec 22, 12 46 33 PM.jpg

    Once you get it finished and start the nut into the headlight switch during installation, you can use a .50 cent piece or a wide, flat blade screwdriver to tighten.
    Photo Dec 22, 12 47 57 PM.jpg
    Photo Dec 22, 12 48 36 PM.jpg

    I hope this is of help to someone. It's a lot of trouble, but it is a remedy.
     
    Brett Slater and Cutlass like this.
  2. gstewart

    gstewart Well-Known Member

    Excellent!!
     
    Jamie Carnes likes this.
  3. Redmanf1

    Redmanf1 Gold Level Contributor

    Nice info***
     
    Jamie Carnes likes this.
  4. HotRodRivi

    HotRodRivi Tomahawks sighted overseas

    I swapped mine out from another switch vacume headlight switch is hard to find.
     
    Jamie Carnes likes this.

Share This Page