August 20-24, 2005
Sometimes I just have to give in to my natural urge to make a big project out of a simple job. There are a lot of things I should do to the car but I was poking around and noticed that the fabric-covered wires from the horn relay to the horns were shedding their insulation. I could have just wrapped them in electrical tape (it is not like I have not done that before). But instead I decided to rebuild the horns entirely.
|Here you can see the frayed wire and the modified upper bracket. There is the remains of a mounting point between the horns that was removed by bending it until it broke. The main mounting bracket on the right was hacksaw-cut to fit. There was surface rust on some of the unpainted horn areas but nothing bad.|
|To separate the horns I had to grind the welds on the shorter horn. I just left the bracket welded to the longer horn. You can see how neatly the metal was cut and shaped.|
|The guts of the horn with the cover removed. The covers just snap on and did a great job protecting the horn mechanism. There was some surface rust on the diaphragm so I cleaned that with steel wool and smeared it with a thin cover of grease. That may have been a mistake but I can always clean it again.|
|Here is the horn mechanism with a new wire installed. I re-used the terminal on the end of the wire to make it look more authentic using the same technique I have used before.|