Sunday was a short day, as Mother Nature denied us the opportunity to accomplish our goals. The plan was to get the cluster and column installed, lower the car and roll it outside, then seal all the floor seams in the great outdoors to facilitate fume removal. I really wanted to get the car out of Stretch's way, and as it happened our timing couldn't have been more precise if we'd planned it.
The first order of business was installing the instrument cluster. Easy, right? Well, yeah, when age doesn't befuddle you it really is. Problem was, I made all the connections at the cluster and still had a bunch of plugs left over that didn't fit it. They were right there, so they had to be for the cluster or switchgear, right? What the... ? So I started taking pictures of them, thinking I'd have to consult with the service manual wiring diagram to find where they went.
For instance, I could not find anywhere to connect this little feller...
And this 8-pin monstrosity definitely didn't belong, but it was hanging out of the cluster hole. Stretch didn't think it had been used, proposing that maybe it was for AC or some option the car didn't have. I didn't rule that out, but for some reason it looked familiar.
After that, I found these two little peckerheads in the same area. These were the key that unlocked my brain. I didn't remember them specifically by color, but the way the wires were bent I knew they were for the brake-lamp switch even though they weren't close to it.
At that point, I realized we'd stuffed every wiring harness we'd disconnected into the dash during disassembly, and when I'd pulled the cluster I looped them up there so they wouldn't repeatedly fall into our way. The three-pin connector in the first photo is for the dimmer switch, and that 8-terminal block is for the rear wiring including taillights and fuel sender. :doh: I reconnected the dimmer, but we still have to seal seams so the rear wiring was left dangling for the time being.
Moving right along after that minor fiasco, I reinstalled the cluster. There's an open pin on the wiper switch for which I could not find a connector, but I haven't had time to research that one yet. Almost a shame to put the detailed cluster into the filthy dash, but I did clean the area around it before I screwed it into place.
The next task was to get the column installed. This was a little more involved than expected, primarily because so much had changed both with and around it. It wasn't just going to slide home and bolt into place. The first problem was that I'd converted the car to manual transmission, so one bracket bolted to the side of the pedal support frame was in position for the car from which the pedals were removed. I loosened that so the two support points at the dash were my reference points. Once I had the toe plate firmly seated against the firewall, Stretch (working the engine-bay side of this job) reported that the coupler shoes were hanging halfway out of the coupler. To be honest, I didn't feel well today and my attitude was "Fuck it, as long as it can be moved we can figure it out later," thought I don't think I said that aloud. Though
he didn't say it, Stretch thought maybe I'd reinstalled the power-steering column shaft after refurbishing and modifying the column jacket. I half-entertained the same thought, but didn't think it was possible. He went inside to get his children some lunch, and I remained there under the dash trying to get all the bolt holes to align since the toe plate did not want to rotate to its original position. While I was staring at those, I remembered that the two that hold the column-jacket flange to the toe plate allow for some movement of the column in relation to the firewall. I loosened those, and after fighting a little bit I got the two-bolt flange to slide and rotate just enough that A) the toe plate holes aligned well enough with the firewall holes to install it, and B) the shoes were now an almost-perfect depth into the steering coupler. Stretch returned, and I sarcastically said, "I don't know what you were complaining about with the coupler shoes," but then immediately told him what the problem had actually been. Installing the steering wheel was a two-man job, though. I installed a junker that hadn't been on a car in awhile (I'm attempting to repair the original) and even with the master spline aligned, it couldn't be pushed on far enough to get the nut started. Stretch held the wheel while I tapped on the center of it with a socket and hammer, and voila! We didn't fully seat it, but it's more than enough for directional control around the yard.
Now we're gettin' somewhere! The skies were threatening at this point, with distant thunder rumbling its own warning that we'd better get a move on. We lowered the hoist to the floor for the first time since March, and the car assumed the standard Upper Peninsula A-body stance--or South Central Impala if you prefer--sitting as low to the ground as possible, right on the snubbers.
Because we replaced the lower-control arm bushings, the torsion bars can't go back in yet. The studs can't be torqued until the car is sitting on its wheels with the weight of the engine on the suspension. So we lifted it again, and Stretch jammed a couple of blocks of wood between the control arms and the frame to give the car a workable ride height. Back on the ground, and we pushed it out of the garage--rolling on its own wheels. :dance:
I cannot adequately express the relief and elation that washed over me whilst taking that picture. Yes, we're a long way from being finished, but this was momentous. All the unfamiliar territory is now familiar. Almost everything from this point forward is old hat for us. Yes, there's still some "body" work to be done on the floors with the seam sealer and paint, and there are some touch-up areas we want to address, but the bulk of the work from this point onward is good ol' fashioned mechanical stuff: Engine, transmission, rear axle, etc.