Bulkhead Connector Stripped Threads?

[dibbons]

The gods above in the firmament just keep throwing monkey wrenches down atop me. Every day is another attempt at re-installing the motor in the '65 Formula S, but another problem seems to always present itself.

This time, I was attaching the two ammeter pass through wires at the main bulkhead distribution block when I found one of them would not tighten up (screw kept turning). Being this is a very key and critical junction, after my cussing session subsided, I figured I could just work a nut onto the other end. It is very cramped in there with power brake booster in the way and I did not want to take the screw out again.

So in order to determine what size nut to use on the screw, I removed the same bulkhead screw from the '65 Signet convertible parked nearby. I had an opposite problem there, the screw turned but would not exit. I found a nut on the other end. That's weird. To the best of my knowledge, the factory did not use nuts. If I am correct about that, I guess a past owner of the convertible must have stripped the threads also, just like me.

Sunday (tomorrow) the fastener store down the street is closed. Monday, I'll be at it again though. First photo is bulkhead connector for Signet, second photo is for Barracuda. It's funny the factory orientation for the Barracuda connector is rotated 90 degrees from the orientation of the convertible.

Last three photos show the screw/nut I removed from the Signet.

 

[Mattax]

To the best of my knowledge, the factory did not use nuts. If I am correct about that, I guess a past owner of the convertible must have stripped the threads also, just like me.

Seems like a reasonable conclusion.
One solution may be to use a square nut instead of a hex. The only advantage this will have is IF its the right size the retainer will prevent it from turning as you finish tightening the screw.

the two ammeter pass through wires

Just so you know, the black output wire from the alternator does not go to the ammeter. It goes to the main splice. From the main splice one branch connects to the battery through the ammeter.

On a '65 there should be a 16 ga fusible link somewhere between the battery and the bulkhead. Maybe right at the bulkhead - factory would be Blue. Some replacements are different colors. I mention it because in the first photo I see a small red wire. For a convertible especially a good connection, and a good crimp there, in addition to the fusible link are all worth the extra effort.

 

[dibbons]

Right, the Barracuda has a blue wire. I will look into the convertible to determine if the fusible link is still there or not.

 

[Mattax]

Here's someone's photo from FABO of '65 that where the fusible link is obvious. I added an arrow.

There might even be two fusible links at the relay. If the horn was fed from that same post, as it was some years, then there might be a fusible link protecting it as well.

 

[Mattax]

You can use this as a start. It shows the general scheme of the main circuits. You can fill in the details and change colors based on what you find and what's in the '65 shop manual.

edit
In the 1965 MTSC they show a fusible link to the horn relay, but the text says that's only on the C-bodies.
page 13 Electrical Accessories & Service (Session 207), Master Technician's Service Conference

 

[65 Dartman]

. It's funny the factory orientation for the Barracuda connector is rotated 90 degrees from the orientation of the convertible.

Is either your Valiant or Barracuda a factory AC car? On an AC car, the bulkhead connector was rotated 90 degrees to clear the AC box.

 

[dibbons]

Barracuda is factory A/C.

 

[dibbons]

Hardware store had some 5/32 threaded nuts (but not square ended), so I put a nut on both terminals even though it was only the top terminal that I could not cinch down tight.

I also plugged in the Park/Neutral start lock-out wire into the solenoid "apparatus". Not quite sure yet how the factory got that wire down, routed, and secured on its way to the switch near the pan of the 904 transmission? It's just a loose wire doing its own thing.