1965 CA77 Ignition Switch Internal Contact Position

[e3steve]

Is this the post that you're looking for?

[bjshealy]

Very close!

The attached photo shows the switch internal circuit ... but I need a photo of the other side of this switch that makes contact to the circuit. The side of the switch I need contains 3 triangle contacts separated approximately 120 degrees apart. Each contact can be inserted in two positions.

Thank you again.

[conbs]

Ever get your switch figured out? I had not seen your post, but had mine apart over the last couple of days. Unfortunately I had not seen your post so I didn't take a picture. But, I know what you are talking about with the triangles. I had to take mine apart again several times to get it right.

Assume you have cleaned everything well. There is a key position that lines up the little notch in the case with the bakelight spring plate and lines up the tumbler to line up slot in the center of the bakelight spring plate. I used grease in the detent springs and balls to hold them together during assembly. They need the lubrication, anyway. Hold them ball-side-up and slide the casing down over them. It is the spring pressure against the bakelite electrical plate that keeps everything together, so once you take the swithc apart, you probably don't want to skip this step as those little balls can slip out pretty easily.

Turn the switch body over. Grease on the springs and triangles to hold everything together. I think all three go with the 2-contact side to the outer perimeter, but I am not sure. If you hold gentle pressure against the bakelight spring plate and carefully turn the key to the "headlight" position, you can put the bakelight electrical plate down against the triangle pieces and see what will make contact. All three have to be making contact as everything is "on" in the headlight position. Be careful that none of the triangles gets knocked off the spring while assembling.

Once you think you have it right hold the switch together with hand pressure and use a continuity tester to check the circuits. Still in "headlight" position, Pink and yellpw make a circuit. Red to all the other contacts should make a complete circuit. If it checks out you can bend the metal tabs back to finish assembly. If not, lift the electrical bakelight plate to see what's wrong. Make sure the circuits all work correctly before bending the tabs back. They will only bend so many times before breaking.

BTW, my electrical bakelight plate had broken out where the tabs bend against it. I tried gorilla glue. Didn't work. J-B Weld did the trick. I took pictures if anyone is interested.

[bjshealy]

Conbs:
Thank you for sharing the information. I for one would like to see your photos of the switch.
I did get the switch to function properly after testing with an ohmmeter in all possible contact positions (8 or 9). Not very difficult after removing and placing on a workbench. My three triangular contacts were NOT all in the same position (inward or outward) but I do not have the diagram with me here today. The switch does need to come out one more time to tighten up (crimp) pressure between metal cover and plastic that is also slightly cracking. A J-B weld repair is in order.
When opened I will take a few photos of the internal contacts to share and demonstrate the correct alignment before final installation. I was plesantly surprised that the three triangular internal contacts were in very good physical condition for a forty plus year old switch!

BJS

[conbs]

Unfortunately my pics didn't turn out too well. They were kind of an after thought. The first one is the finished product after carefully taking a file to the JB Weld. Mine was broken out pretty badly so the JB Weld had a good bit of area to fill and I think ended up stronger as a result. If your bakelite is only cracked, I am not sure how this will work. You might be able to pile JB Weld on the wire side of the bakelite plate to hold eveything together.

The second photo shows the result after I put the JB Weld into the repair area. I used a tooth pick to mix the 2 components and then used it to apply the JB Weld. Read the instructions. You should let it sit for 15 minutes before putting it on. I then put the bakelight on a piece of paper with the contact side down (like the second picture), prop it up so the bakelight plate lays flat against the surface below it and let the JB Weld set up overnight.

I then put a piece of sandpaper on a very smooth granite surface (not the kitchen counter in the picture) and smoothed the contact side to remove the excess JB Weld. This creates a nice smooth surface for the trianlgle contacts to run on and cleans the contact areas as well. Finally, per the first picture I took a file to the perimeter to round off the JB Weld so the bakelite plate would fit down in the switch housing.

I should have thought to take more pictures, but I wasn't sure the operation would be a success. The patient seems to have recovered fully is now living a normal life in Dream Land.

Hopes this helps someone.

[bjshealy]

Great news!!

Just took some photos of the correct internal contact positions for the CA 77 Combination/Ignition switch.

Hope to get the photos posted tomorrow.

Really quite simple after disassemly/assembly several times with diagram.

[b]Caution[/b]: .... once apart, do not force switch halves back together because contacts and insulators can (and do) shift out of position quite easily.

[bjshealy]

Technical difficulty uploading internal switch contact photos for now.

However, the 3 triangular contacts should be positioned as follows:

1. remove key from off position.

2. split switch in half...triangular contacts on one side, wire connections on the other.

3. set open slot in switch contact body at 12 o'clock position.

4. install first triangular contact at 12 o'clock position with single contact facing outward.

5. install second triangular contact in 4 o'clock position also with single contact facing outward.

6. install third triangular contact in the 8 o'clock position with the double contact facing outward.

7. carefully assemble wire connection switch half to triangular contact half.

8. Test all switch key positions (5 or 6) with ohmmeter using Switch Matrix Diagram.