Back at the molding process . The ***** for the triangular shaped control panel are molded on the cables . After many months the molding process has begun .Made the silicone mold this evening . Will mix some correct color liquid plastic &pour it into the mold thur.Will post some pics . So if all goes according to plan will be able to cast new ***** onto your cables soon .

 

You can buy the ***** and cables cheap on ford parts sites. These ***** were $2 and I found the heater switch on ebay for $18.

 

I expect firstrider's ***** to be very accurate reproductions of the original. The restoration work he has posted is very correct. I admire his persistence on making things "as Henry built it", to borrow the phrase from the Early Ford V8 Club.

 

Your source for the ***** / cables please .

 

Its been a while since I did that but I recall it wasnt hard to find the parts. Most everyone that sells vintage ford parts carried them. Early Ford, midwest, maybe even DC. They were ford car ***** and cables from the 40's but they worked just fine and connected to my magic air box controls.

 

Pics of the cables:

 

Looks like you need a defrost y-duct for your Magic air heater & some defrost hose Have 30 y-ducts here & some original style black canvas w/ a wire helix defrost hose . Maybe look thru your receipts for the source of the cables w/ ***** .

 

**** reproduction process . The yellow **** was from the 1st attempt months ago .Result was loss of interest by owner .
Made new silicone mold . Tiny air bubbles in this mold but getting closer . Made another silicone mold today as it was raining anyway & poured it around original **** . Tapped container as it was being poured to insure air traveled to the top .Let it sit overnite & remove fri. am. The liquid plastic sets up in 15 min. so will be able to make 3 / hr. Pics fri. eve.

 

I have all the parts, took pic when I was putting it together. Since most of the control ***** can be purchased for $2 I wouldnt waste my time on those BUT the switch and **** would be worth it. Find a decent modern switch and make ***** for that, its where the money would be since the switches are rare, not to mention that 65 year old switches have seen their day.

 

Made some progress . These will work on the'48-'50 cable control panel .

 

Johnfin , try to reach back in the memory bank & see if you van remember where those ***** came from . Have searched DC, Early ford & etc. with no results .Thanks , Denny

 

Denny those ***** look good. When you get it perfected you can restore my magic air. I think originals are more tan. Do you plan on painting them or coloring them prior to casting?

 

Nice work Denny.

 

This is what the inside of a '48 -'50 blower control **** looks like . The metal cylinder which turns the switch / motor to off -low & high is cast into the **** . I have 2 of the metal cyl.. You can see the difficulty in making these but will give it a try .

 

One of my friends got really into casting plastic. His best process for a flaw free casting involved pulling a vacuum on the mixed up plastic before pouring to pull out any gases, then putting the mold into a pressure pot to squeeze any remaining bubbles down so they were so small you didn't notice them.