27 Sept 2020 - headlight wiring harness - parts, tools

I ordered a couple more parts and a crimping tool.  I do have a crimping tool but it is not working well.

ordered:

• 2 kits, H4 terminals and receptacles.

• H4 terminals, 42663-2, 100 pcs(min order)

• 1 1/4" rubber panel plug(automotive style) kit

• Astro Pneumatic Tool 9477 7-Piece Professional Quick Interchangeable Ratchet Crimping Tool Set

14 Sept 2020 - headlight wiring harness parts

The headlight bulb connector kit arrived today.

Still waiting on the 3 pin flat connector kit.

12 Sept 2020 - Headlight Harness Mod

 Purchased the final components necessary to build upgraded headlight harnesses for the cougar.  The original harnesses are 50+ years old.

The wire colors will not match the factory wires.  Not a problem, I will update my collection of schematics.

 

 

6 Sept 2020 - Exterior cleanup

 Started cleaning up the exterior of the car.  The paint is getting faded again.  I bought a product that is very similar to TurtleWax Colorback.  Its called Meguiars Ultimate Compound.

It seems to work well.  I have the hood and the tops of the two front fenders completed in 1 coat.  Still working on the rest of the car.

2 Sept. 2020 - headlight wiring harness

Considering replacing the headlight wiring harnesses.  Since installing the relay kit for the headlights, I noticed how old and worn the harnesses for the headlights appear.  The plan is to replace the wiring with 14 gauge wiring, replace the connectors with ceramic connectors and just generally beef up the wiring harness where ever possible.

The flat style connectors Ford used, are called hopkins connectors and reese connectors.

25 August 2020 - Defogger

Continued with cleaning up hardware/pieces parts.  The switch mounting bracket has been cleaned up and primered.  When that is cured, a top coat will be applied.  Still looking for a 3 position switchto replace the original.

23 August 2020 - Rear window defogger

 Cleaned up the unit.  It comes apart pretty easily.  The lower shroud is plastic and the upper motor shroud is some type of pot metal.  The ground and power wires from the motor are in very good shape.  The power wire is missing the connector.  The wiring harness that came with the unit has been cut up and is missing the resistor wire section and the other end of the connector to the motor unit.  The defogger switch assembly is in good shape, it does switch from off to on, on without issues and the contacts are clean.  The mounting bracket had rust, so I have stripped the paint and the part is soaking in Krudd Kutter rust remover/converter.

It looks like I will have to build a wiring harness for the defogger.  I will try to make it function so that there is a high speed and low speed.  I am looking into obtaining automotive resistor wire for applications like this wiring harness.