babychadwick Posted November 8, 2019 Share Posted November 8, 2019 As I source proper coils to be replaced inside the coil and it's apart I decided to make a replacement plate. While I don't intend on running the car with the plate it makes for a nice spare should something happen to the original. Supplies needed: An epoxy mixture (a table top epoxy able to be purchased at a hardware store may work for you) Milled/powdered fibers (May be your hardest item to source) Playdough (3-6 jars) Kitchen no stick spray Suitable sized bowl or other container Tape off the brush and points contacts so there is no inverted edges. Fill bowl with playdough Spray coil with non stick Press coil into playdough and remove Carefully fill screw holes and point brush voids Mix epoxy and fibers and pour in Bubbles will form and rise, it is possible to accelerate the rise of bubbles by lightly dropping the bowl as you would a cake. Bubbles can be popped by blowing gently on them. Link to comment Share on other sites More sharing options...
babychadwick Posted November 8, 2019 Author Share Posted November 8, 2019 Pressed in and filled with epoxy Link to comment Share on other sites More sharing options...
babychadwick Posted November 8, 2019 Author Share Posted November 8, 2019 The epoxy and fibers Link to comment Share on other sites More sharing options...
babychadwick Posted November 8, 2019 Author Share Posted November 8, 2019 After sitting overnight the new plate ready to be cleaned and drilled. Link to comment Share on other sites More sharing options...
babychadwick Posted November 10, 2019 Author Share Posted November 10, 2019 Once the plate is cast the next step are the connections. The brushes I pulled from a 1980 super beetle distributor cap, the hole drilled was 3/16. Link to comment Share on other sites More sharing options...
babychadwick Posted November 10, 2019 Author Share Posted November 10, 2019 Once drilled I tapped it out to a 12-24 thread, the cut on threads is light but enough. Using a 12-24 screws the end is tapered and cut to the proper length so it will connect with the brush from the bug cap. Link to comment Share on other sites More sharing options...
babychadwick Posted November 10, 2019 Author Share Posted November 10, 2019 A couple nuts are locked together and then turned down and the screw head is rounded to accept a female plug fitting Link to comment Share on other sites More sharing options...
babychadwick Posted November 10, 2019 Author Share Posted November 10, 2019 To make the connection inside for the points I taped and threaded screws with a lock nut so I could screw it in to make contact then lock it into position. From this point it was a matter of picking ballast resistors, coils, mounting and wiring. All in all withing 48 hours a point of no coil to running car, I drove it tonight! Link to comment Share on other sites More sharing options...
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