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Rebuilding A Junker Cutlass Into A Kinda-Sorta Faux-Four-Two Musclecar, Part 4:
The relays for the headlights worked, but I needed a place to properly mount them to keep them secure.
I decided to mount them in the engine compartment, near the battery, where the relays could be fed by a
short, fat wire to get full power to the lights. I got out some thing cardboard, made a few measurments,
and sketched up a workable design.
That design got transferred over to a piece of fresh 22-gauge sheet steel, and carefully cut out and trimmed.
A little careful work got it bent up into this boxy shape...
Which was then carefully TIG welded at the seams.
now, I needed a couple of mounting points, and rather than just drilling a self-tapping screw,
I used a Whitney punch to pop two sets of three holes, like so.
That let me very carefully TIG weld a 1/4"-20 nut to the inside of the box form.
After those were ground smooth , a little measuring and drilling finished the fabrication.
That assembly gets the relays and a trio of fuse holders bolted to it (one fuse for each relay, one relay for each
pair of filaments) the wiring cleaned up a bit, and then bolted into place using some existing holes in the fender.
With it fitted and tested, I pulled it back out and gave it a couple coats of black paint.
And, as a little extra protection, I cut out this "flap" from some surplus treadmill belt, and popped
a couple of matching holes so it would be captured between the mount and the fender.
And installed, wired and tested
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