Auto Headlight Control Modification
IF THE IMAGE IS TOO SMALL, click it.
Because of its compact & intuitive design, and its ease of mounting, I decided to use this '90 Cougar control switch. Unfortunately, its internal circuitry creates problems for me, and rather than solve them externally, I'm redesigning it internally.
1. The front bezel is VERY brittle, so be careful removing it. Pry between each wheel's axle & the center of the housing to release their axles and pull the guts straight out. The wheel slide off, and after unfolding the bulb from its well, the board can be released from the brace. I washed this one with brake cleaner (electrical contact cleaner would have been better, if I had some) and polished it with ultra-fine steel wool. I applied electrical grease to the traces before I realized I'd be modifying it. I washed the bezel with Purple Power & hot water with a hospital brush, then sprayed it with Krylon Fusion UltraFlat Black, and put it in a toaster oven for a few minutes. Then I sanded it lightly to reveal the lettering.
2. The black marker shows where the trace needs to be cut for my modification. The heavy black strips are resistor material.
3. I carefully tinned the traces, keeping the heat to a minimum, and keeping the solder just at the edge of the wiper trace. I also removed the bulb wire and created a solder bridge at the top R.
4. Again keeping the heat to a minimum, I soldered on my jumper wire.
5. Using a sharp knife & pick at the top L near the rivet, I opened a gap in the trace to isolate the sections and create the circuitry I need.
6. On the other side, I taped over a trace to insulate it, and soldered the bulb lead back down.
7 & 8. The gray jumper wire is very carefully bent & trimmed so as NOT to interfere with the wipers.
9. No difference is apparent, but its electrical behavior has changed.
![autodial.jpg Auto Headlight Control Modification
IF THE IMAGE IS TOO SMALL, click it.
Because of its compact & intuitive design, and its ease of mounting, I decided to use this '90 Cougar control switch. Unfortunately, its internal circuitry creates problems for me, and rather than solve them externally, I'm redesigning it internally.
[url=http://www.supermotors.net/registry/media/907876][img]http://www.supermotors.net/getfile/907876/thumbnail/autolampsbrights.jpg[/img][/url]
1. The front bezel is VERY brittle, so be careful removing it. Pry between each wheel's axle & the center of the housing to release their axles and pull the guts straight out. The wheel slide off, and after unfolding the bulb from its well, the board can be released from the brace. I washed this one with brake cleaner (electrical contact cleaner would have been better, if I had some) and polished it with ultra-fine steel wool. I applied electrical grease to the traces before I realized I'd be modifying it. I washed the bezel with Purple Power & hot water with a hospital brush, then sprayed it with Krylon Fusion UltraFlat Black, and put it in a toaster oven for a few minutes. Then I sanded it lightly to reveal the lettering.
2. The black marker shows where the trace needs to be cut for my modification. The heavy black strips are resistor material.
3. I carefully tinned the traces, keeping the heat to a minimum, and keeping the solder just at the edge of the wiper trace. I also removed the bulb wire and created a solder bridge at the top R.
4. Again keeping the heat to a minimum, I soldered on my jumper wire.
5. Using a sharp knife & pick at the top L near the rivet, I opened a gap in the trace to isolate the sections and create the circuitry I need.
6. On the other side, I taped over a trace to insulate it, and soldered the bulb lead back down.
7 & 8. The gray jumper wire is very carefully bent & trimmed so as NOT to interfere with the wipers.
9. No difference is apparent, but its electrical behavior has changed.](https://www.supermotors.net/getfile/907877/fullsize/autodial.jpg)