removing headlight harness from support tube

[Rudy Bernhard]

While trying to remove the headlight wiring harness from the support tube, pulling from the battery box is not giving success. Compressed Air blown into the hole in the battery box does not result in air coming out in the headlight bucket. Any hints on removing the stuck harness? Is this rust or dirt/sand in the support tube? Any experience on the best way to proceed, or do you just replace the bucket support structure? We are replacing the headlight bucket anyway. New Mexico car, so not a lot of rust elsewhere. 63 T6B Coupe.

Thanks, Rudy

[Phil Planck]

Remove bullet connectors. Cut away as much sheathing as you can. Pull one wire at a time.

[Mike Wilson]

I had the same problem with one side of my car. I tried pulling one wire at a time; no go. Then tried reaming out as far as I could reach; still no go. Finally used a long drill bit to clean out as much as I could figuring it might be loaded ip with rust and/or crud. This after liberal application of Kroil. Then went back to pulling one wire at a time. I finally managed to start pulling wires but then found out the problem. There had at one time been a short in the wiring melting the plastic sheathing to the inside of the support tube.

Since the car is in restoration and the support tube has rust holes any way, the entire support tube/brace is being replaced.

Mike Wilson
Lomita, CA
'63 B coupe

[Martin Benade]

If the problem is not as severe as Mike's, possibly heating up the outside of the tube with a heat gun could help. That worked well for me, allowing the complete bundle to come out together.

[Mike Wilson]

Great suggestion, Martin. Heating it won't destroy the support tube either.

Mike Wilson
Lomita, CA
'63 B coupe

[Rudy Bernhard]

Martin, when it did come out, was there any crud, or was it just the sheathing and insulation had hardened up?

Rudy

[Martin Benade]

I think there was some dirt, etc but maybe they were not stuck as badly as yours are.

[Rudy Bernhard]

moderate heating of the tube in the fender well was the key. But the outer wire sheath was stuck on some dirt in the tube, and the sheath split in the battery box. With the help of lubricant, the individual wires came out first. The empty sheath was removed second, after it let go of the dirt/crud in the tube.

No movement without the heat though. The wire insulation stiffens with age, and flexes after heating.

[Mike Wilson]

Success! Glad to hear it!

Mike Wilson
Lomita, CA
'63 B coupe