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Old 11-26-2012, 07:45 AM   #171
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Re: El Tortuga...update 11-13-12!

after driving the bus wensday to pick my son up from college and I needed to bring home some 20/24 foot metal,I relised the headlight output sucked badly.
This was the first time to drive at night with the bus,I have had an intermitten issue with dash lights going out since I have had it.
The lights where yellow looking and not bright.
I started looking for a bad ground, I pulled the lights notice anything?

you can see the element!!!

this was the worst one, no mirror surface left!!!!!

I pulled the headlight switch out and found this...burnt wires

The main 12v in was burnt, after taking switch apart and finding it melted inside...a new one was needed,I replaced the switch.

I also cut out about 12 inches of the power wire,soldered a new lead in
and after adding up the headlights on high beam 2 @ 60 watts and 2 @ 55 watts I was at about 18.5 amps,then if you factor in the 12 marker/parking lights I was actually well over the rated load carrying for 12 ga wire.
so I wired in a seperate 12v 20 amp circuit for the park and marker lights with a simple switch.
now I only have headlights on the circuit and should be good from here on out.
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Old 11-26-2012, 12:59 PM   #172
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Re: El Tortuga...update 11-13-12!

Good fix. You might want to put a little dieelectric grease on the new headlamp terminals. It helps stop the development of a high resistance short as the terminals begin to corode due to moisture. I have seen many car fires which were started by high resistance shorts in the lighting system. My two cents worth. Jack
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Old 11-26-2012, 02:04 PM   #173
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Re: El Tortuga...update 11-13-12!

yup,I need to get some more...it comes in such little tubes I always lose them after using just one use
I was just amazed at how much crap they were pulling off just a 12 ga wire
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Old 11-26-2012, 02:06 PM   #174
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Re: El Tortuga...update 11-13-12!

Nice job......... It'll be nice to be able to see at night...
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Old 11-30-2012, 05:29 PM   #175
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Re: El Tortuga...update 11-13-12!

where to start...big plans to knock out the horn install and an aux tank for tools and tire inflation.
Mmmmmmmmm...how did it go you ask.....well it started at 21 degrees.
blagh,blagh,blagh...I grab the horns,valve and tubing,no worries...yugh...right

the threads were not 1/4 NPT like they looked, so fitting didn't screw in...no big deal we'll just drill it out and tap it.
nope....to do this you have to take them apart so you caan blow out the chips etc.
screws had reacted(badly) being dissimilar metals as they do....

so I entered the building of doom and found this.
4 broken bits later(they were to "hard"...yes there are 3 in the pic...I threw one )

so I had one left that would not come out...argh....so I grinded it off flush.

which ment I had to drill and tap 3 holes 6-32

so now to work on air inlet.
once again I entered the domain of satans flying dive bombers (thank god it's cold out )

okay hole is drilled 7/16...crap where is my tap???
to town I went 45 min later part is clamped to something heavier than my lap and hands...

ooohh look, threads..
that is porosity not a torn thread

oh did I mention I had to drill some mounting holes for it??? nope...two .343 holes for a couple 5/16 bolts


i just sprayed it down with brake cleaner...blew it off and sprayed it with Almond real quick.
I brought it inside to dry...and I'll be damned...dropped it in spare bedroom...arggghhh...it's okay tho'
The cat hair stopped it from getting on the carpet....

let's see what tomorrow brings!!!!!!!!!
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Old 11-30-2012, 07:52 PM   #176
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Re: El Tortuga...update 11-30-12!

Hey Bansil, laughing with you not at you. Isn't that the way those things go just when you think you've got things under control? Can't help but wonder what those threads were originally. Anyway, nice save and now you can blow your own horn--so to speak. Jack
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Old 11-30-2012, 08:37 PM   #177
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Re: El Tortuga...update 11-30-12!

Sure glad someone had a GREAT! Day.......
Keep us posted. This is entertainment at it's best. Getting to laugh with you..... Congrats..
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Old 11-30-2012, 09:35 PM   #178
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Re: El Tortuga...update 11-30-12!

Thanks for sharing, made my day better.
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Old 12-01-2012, 05:48 AM   #179
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Re: El Tortuga...update 11-30-12!

You are all welcome
Jack they were a straight 7/16-20,I'm guessing it had a npt threaded stud so a nut would tighten down as a mounting bolt,and then the hose connection was threaded in.
And since I really didn't want to make another weird stud,I just made my own mounting holes and npt port.
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Old 12-03-2012, 09:17 AM   #180
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Re: El Tortuga...update 11-30-12!

The rest of the story
I drilled holes to mount the horns

I made a bracket for solenoid

and mounted it up front

here they are!

I like them,
my wife said"so you mounted them outside,not hidden underneath...you just had to make it more redneck hugh?.. .. "
REDNECK???...Honey it is a Skool bus...
We both started to laugh..
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