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Question about 55-56 Mopar voltage regulator firewall mounting
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56D500boy
Posted 2021-01-03 9:54 PM (#607388)
Subject: Question about 55-56 Mopar voltage regulator firewall mounting



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I might need to move my 56 Voltage Regulator more towards the driver's side of the firewall for my evolving Power Brake (PB) modernization project (to get clearance for the new PB booster). There are a few conflicts to overcome but nothing too serious, i.e. nothing a Dremel and/or a drill can't handle).

What I was wondering about is whether the OE mounting holes on the firewall are just tapped and threaded or is there a nut that was welded to the interior side of the firewall. I can drill and tap (and I guess, if need be, add Nyloc nuts on the inside). I just want an idea what I am up against.

Today's investigation:

Edited by 56D500boy 2021-01-03 11:06 PM




(56Dodge12VRegulatorInNormalLocationWith2boltsRemoved.jpg)



(56Dodge12VRegulatorBoltsRemovedAndSlidOver.jpg)



(56Dodge12VRegulatorRemovedShowingOEMountingHoles.jpg)



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Attachments 56Dodge12VRegulatorInNormalLocationWith2boltsRemoved.jpg (112KB - 15 downloads)
Attachments 56Dodge12VRegulatorBoltsRemovedAndSlidOver.jpg (99KB - 15 downloads)
Attachments 56Dodge12VRegulatorRemovedShowingOEMountingHoles.jpg (111KB - 16 downloads)
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56D500boy
Posted 2021-01-04 1:48 AM (#607391 - in reply to #607388)
Subject: RE: Question about 55-56 Mopar voltage regulator firewall mounting



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While I await confirmation/denial of captured nuts or threaded firewall holes, I checked out some of the photos from my "X-rated" (naked) firewall thread.

http://www.forwardlook.net/forums/forums/thread-view.asp?tid=75003&...

One of those photos, the one from GaryS of the naked inside of a 56 Belvedere is intriguing. I copied the photo and doubled the size and then trimmed it. I don't think that I see any captured nuts on the interior side (see below). I also have figured out that the bolts used to hold the regulator to the firewall are likely the same size and thread pitch, i.e. 1/4-20, flange-head bolts as the ones that hold the fiberglass 55-56 heater boxes to the 55-56 firewalls.

I doubt that that many holes would have captured nuts welded to the inside of the firewall. Hence, I am thinking that they are all tapped/threaded holes. (???)

GaryS's photo (segment):



Edited by 56D500boy 2021-01-04 2:08 AM




(GarySs56BelvedereFirewallFromTheInside.jpg)



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Attachments GarySs56BelvedereFirewallFromTheInside.jpg (84KB - 16 downloads)
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Powerflite
Posted 2021-01-04 8:06 PM (#607420 - in reply to #607388)
Subject: Re: Question about 55-56 Mopar voltage regulator firewall mounting



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The metal was bent inward first, creating a better surface for threading. If you just drill a hole, you will need to use a sheet metal screw instead.
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56D500boy
Posted 2021-01-04 11:18 PM (#607424 - in reply to #607420)
Subject: Re: Question about 55-56 Mopar voltage regulator firewall mounting



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Powerflite - 2021-01-04 5:06 PM
The metal was bent inward first, creating a better surface for threading. If you just drill a hole, you will need to use a sheet metal screw instead.


Thanks for that Nathan.

So what if I drill the pilot hole for the 1/4-20 tap (e.g. "For a 1/4-20 bolt, the optimal drill bit size is #7 or 13/64th") and then use a punch to bend the hole in a bit before I start the 1/4-20 tap? I want to reuse the OE bolts if possible (for a quasi-OE look).

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56D500boy
Posted 2021-01-05 2:50 AM (#607428 - in reply to #607424)
Subject: Re: Question about 55-56 Mopar voltage regulator firewall mounting



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I was out at the car today re-installing the shifter box in the polished shifter housing and when I got done that, I played with the position of the voltage regulator. The diameter of the PB booster that I am using is about 10.75" (i.e. I need to clear the driver's side edge of the booster that is 5 3/8" from the centerline of the pedal bracket mount. If I notch the mounting frame of the voltage regulator, I think I can get the regulator over enough to have a straight shot at the mounting bolts and the screws that hold the wires to the regulator. Something like this "Paint" mock-up:

First "Before" and then "After":





(VoltageRegulatorBaseSmall.jpg)



(VoltageRegulatorMovedOver_1.jpg)



Attachments
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Attachments VoltageRegulatorBaseSmall.jpg (153KB - 15 downloads)
Attachments VoltageRegulatorMovedOver_1.jpg (231KB - 16 downloads)
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Powerflite
Posted 2021-01-05 5:02 AM (#607429 - in reply to #607388)
Subject: Re: Question about 55-56 Mopar voltage regulator firewall mounting



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That should work. Just use some washers to clamp it down on one side and drill a single small hole for a sheet metal screw on the other side.
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56D500boy
Posted 2021-01-05 5:48 PM (#607439 - in reply to #607428)
Subject: Re: Question about 55-56 Mopar voltage regulator firewall mounting



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Went to sleep thinking about a better way to mock up the voltage regulator without causing damage. Decided on a cardboard template.

In the AM, I found my spare voltage regulator and used it to trace the size and shape of the base plate. I cut it to shape and then added some silver and blue (couldn't find black) tape to mock-up the regulator.

Then I took it out to the garage for a trial. I think that if I try harder and drop it down a bit more, that I can move it about 1". At this point, the distance is about 3/4" (+/- 1/16").

Assuming that the diameter of the new PB booster is 10.75", the radius that I need to clear for the edge of the regulator case is 5 3/8". I am close to 5.75" now with a possiblity of more so I think that it will be good enough to have clear and easy(ish) access to the voltage regulator wire hold down screws.

EDIT: Went out to the garage to do an insitu polish of my pot-metal shifter housing (with WENOL) and, while I was there, I trimmed the voltage regulator template so it was about 1/8" down and 1/8" more to the driver's side fender. (No photos). Looks more like I will be able to move it very close to 1" over giving the case about 1/2" clearance from the PB booster. I trust that will be enough. (??!!)



Edited by 56D500boy 2021-01-05 11:17 PM




(56DodgeVoltageRegulatorMockUpPinnedInPlaceWithOEBolts.jpg)



(56DodgeVoltageRegulatorMockUpTrimmedAndTapedInPlace_2.jpg)



(56DodgeVoltageRegulatorMockUpTrimmedAndTapedInPlace_Measurements.jpg)



Attachments
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Attachments 56DodgeVoltageRegulatorMockUpPinnedInPlaceWithOEBolts.jpg (167KB - 12 downloads)
Attachments 56DodgeVoltageRegulatorMockUpTrimmedAndTapedInPlace_2.jpg (213KB - 12 downloads)
Attachments 56DodgeVoltageRegulatorMockUpTrimmedAndTapedInPlace_Measurements.jpg (238KB - 12 downloads)
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22mafeja
Posted 2021-01-06 3:00 AM (#607447 - in reply to #607439)
Subject: Re: Question about 55-56 Mopar voltage regulator firewall mounting


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I know you love the oem stuff Dave but have you considered moving the voltage regulator to an other location or even using a smaller one?
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56D500boy
Posted 2021-01-06 3:53 PM (#607460 - in reply to #607447)
Subject: Re: Question about 55-56 Mopar voltage regulator firewall mounting



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Location: Lower Mainland BC
22mafeja - 2021-01-06 12:00 AM
I know you love the oem stuff Dave but have you considered moving the voltage regulator to an other location or even using a smaller one?


Considered? Yes.

For how long? About 2 milliseconds

I'm quite confident that by moving the regulator over and slightly down I will gain the required clearance to the OEM regulator wiring harness in the future, without any difficulty.

(I hope).

Your suggestion(s) Ralf will be Plan B.



Edited by 56D500boy 2021-01-06 3:53 PM
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56D500boy
Posted 2021-01-06 9:16 PM (#607465 - in reply to #607439)
Subject: Re: Question about 55-56 Mopar voltage regulator firewall mounting



Expert 5K+

Posts: 6970
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Location: Lower Mainland BC
56D500boy - 2021-01-05 2:48 PM
EDIT: Went out to the garage to do an insitu polish of my pot-metal shifter housing (with WENOL) and, while I was there, I trimmed the voltage regulator template so it was about 1/8" down and 1/8" more to the driver's side fender. (No photos). Looks more like I will be able to move it very close to 1" over giving the case about 1/2" clearance from the PB booster. I trust that will be enough. (??!!)


While I had the camera out to take photos of the polished shifter housing today, I snapped a photo of yesterday's trimmed voltage regulator template moved about as far over and down as I think is going to be feasible.

This:



(56DodgeVoltageRegulatorMockUpMovedAboutAsFarOverAndDownAsFeasible.jpg)



Attachments
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Attachments 56DodgeVoltageRegulatorMockUpMovedAboutAsFarOverAndDownAsFeasible.jpg (146KB - 12 downloads)
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