1963 Headlight Headlamp Dimmer Switch Restoration

[Richard M.]

I have a Headlight dimmer switch that came from a '63. I did a quick test using my ohm meter. Very high and intermittent resistance. Here's the movie....

Here is a process to open it up and repair/restore.

To open one up use a small hammer and a drift to bend back the 4 small peens in the case. Don't get too aggressive, light taps.
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Remove the terminal cover block. Then retrieve the round fan shaped copper contactor and plastic rotating cam mechanism.
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The slotted hole fits over the button lever stud.
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Remove the push button by tilting its end tab out of the case. Retrieve the button and big spring.
You can see the button lever stud at the end of the lever.
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Here you can see the dirty contacts on the terminal block. This and the rotating contactor will be cleaned using my fiberglass eraser tools.
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When you push the button it rotates the copper contactor tabs to one of 2 positions, high or low beam.
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Here is the grungy case after opening it up. This will be cleaned via light glass media blast.
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The button end.
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I'll follow up after repair with the "Afters" and another test video.

Rich

[Richard M.]

Re: 1963 Headlight Headlamp Dimmer Switch Restoration

I finally got around to finish up this switch repair. It was decided not to do a full restoration, per se, as my friend asked to leave the exterior alone. So we have a nice 60 year old looking floor dimmer, with a fresh new interior and perfectly functional.

I cleaned the internal case of all of the old dried up lithium grease. Then I cleaned the cam actuator and rotating cam, along with a good cleaning of the copper contact fan and the button contacts on the backside of the terminal contactor assembly. I also cleaned the terminals. I used a combination of my wire brush drills, fiberglass erasers(course and fine), and my wire wheel.

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For the moving parts, I prefer silicone lube. Just a small amount at the foot button shaft areas and all rotating points.
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I then install the cam actuator.
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Then the rotating cam and spring assembly.
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Then the copper contactor "fan". Its mating 3 cam edges lock into the plastic rotating actuator.
Then the terminal contactor assembly is positioned over the contactor fan. It may take a little wiggling to get the shaft to line up into the mating hole in the terminal block.
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I set the assembly in a vice and firmly stake the case in four places as was originally done.
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Then I tested it using my ohm meter. It now yields very consistent readings of "CLOSED" in both positions, 0.1 ohms in both. It's now a switch, not a variable resistor as shown in the video when I first tested it.
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This final test proves that most 50 to 70 year old dimmer switches are very overdue for a overhaul.

Rich

[Leo G.]

Re: 1963 Headlight Headlamp Dimmer Switch Restoration

Rich, Very informative and helpful. Also extremely well done as usual. Thank you!

Drive em safe
Leo

[Richard M.]

Re: 1963 Headlight Headlamp Dimmer Switch Restoration

Thanks Leo.

Update: Dave Z created a PDF for download for future reference. I've Attached it here for now and I'll add it to our DoRD Sticky in the future.

Thanks Dave!