DIY Network

1962 Ford T-Bird Restoration: Ignition-System Upgrade From "Classic Car Restoration" episode DCR-307

The points in breaker-point ignition systems tend to get pitted, corroded or wear out and if they aren't changed annually. For our 1962 Thunderbird, we replace the stock ignition with a new electronic ignition system.

In this segment, the 1962 Thunderbird gets an ignition-system upgrade with an electronic ignition replacing the old points-ignition system for more reliable start-ups.

Materials:

Standard automotive tools (socket wrenches, extensions, combination wrenches, screwdrivers, nut-drivers, etc.)
Air compressor and impact wrenches (optional)
Electronic ignition kit
Replacement distributor cap
Replacement sparkplug wires
Sparkplugs
Sparkplug gapping tool
Anti-seize compound
Needle-nosed pliers

Safety Equipment:

Work gloves
Safety glasses or other eye protection

Safety Alert: Always wear eye protection when working with power tools or pneumatic tools.

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Figure A

Note: This is a summary of steps included in the automotive restoration procedures shown in this episode of Classic Car Restoration. These are general guidelines for restoration procedures on this particular make and model of vehicle, and for the level of restoration selected for this project. There may be variations in procedures depending on model, condition of vehicle, level of restoration undertaken and the types of replacement parts or upgrade kits selected. Always follow proper safety precautions, and read and follow manufacturer's guidelines, diagrams and safety notices that come with any replacement parts or kit that you select.

Ignition-System Upgrade

The ignition on our 1962 Thunderbird project car is a mechanical breaker-point type. Although breaker-point ignition systems were known to be fairly reliable, they do require regular maintenance in order to maintain good horsepower, clean emissions and easy starting. Typically, over time, the points in these older ignition systems tend to get pitted or corroded, or just wear out and if you don't change them annually.

As an upgrade to our T-bird, we opted for a direct bolt-in kit that replaces the breaker plate and points with solid-state magnetic-trigger components. The manufacturer of this kit claims a doubling of the spark energy that will provide reliable ignition, cleaner emissions and more horsepower along with a smoother idle and faster start-up. This is a fairly straightforward installation that shouldn't take long.

• Begin by taking the distributor cap off (figure A). Once disconnected, set it safely out of the way.
  
• With the distributor cap removed, pull the rotor off (figure B).

• Remove the breaker plate that houses the contact points and pivot arm (figure C).

  Figure B

  Figure C

  
  
• Disconnect the coil wire at the negative side (figure D).

• Remove the condenser from the distributor housing (figure E).

  Figure D

  Figure E

  
  
• Using the needle-nose pliers, carefully flatten the wire terminals that were bent earlier so that they can now be attached to the coil. Attach the black wire to the negative side of the coil (figure L) and the red wire to the positive side.

• Re-attach the wire that comes from the ballast resistor and ignition key (figure M), and tighten down the retaining nut.

  Figure F

  Figure G

  
  
• Now the parts removed earlier can be reinstalled. However, we opted to upgrade these components adding a new cap, rotor, plug-wires and plugs. So we discard the old rotor and replace it with a new one (figure N).

• We also replaced the original distributor cap with a new one (figure O).

  Figure H

  Figure I

  
  
• The conversion kit replaces the old breaker plate with a solid-state ignition module and magnetic trigger ring (figure F). The sensor on the end of the module transfers magnetic signals into electronic signals which fire the sparkplugs. There are no moving parts, and the unit produces twice the spark output of the old system. This results in better fuel economy, more power, faster startups and longer plug-live.

• Because the terminal ends won't fit through the existing hole in the distributor housing, the terminals are bent slightly using needle-nosed pliers. Then the wires can be inserted through the hole. Pull the wires until the rubber grommet seats in the hole (figure G). This will form a seal that will help keep moisture out of the distributor.

  Figure J

  Figure K

  
  
• Attach the ground-wire and screw to the base of the new unit (figure H) and secure the new module onto the plate with its mounting screw (figure I).

  Figure L

  Figure M

  
  
  
• Important: When installing the plug wires on the new distributor cap, it's critical that each wire be installed to the correct terminal. If the wires get connected in the wrong locations or sequence, the firing order on the motor will be incorrect, and the engine won't start. To prevent this from happening, transfer the wires from the old cap to the new one, one at a time, using the old cap as a reference (figure P).

• Inspecting the interior of our old distributor cap, it's apparent that the contacts are becoming worn (figure Q). The electronic erosion of these terminals is typically what wears out on distributor caps through use and wear. We discarded the old distributor cap.

  Figure P

  Figure Q

  
  
• We opted to change out the sparkplug wires, upgrading to high-quality silicon 7mm wires (figure R). These will help ensure a good link between distributor and sparkplugs.

• Again, when installing the new wires, be sure to connect them to the proper terminals. We pulled each wire out, one at a time, and compared it with the new ones to select the right length and ensure proper connection (figure S). Install each wire, making sure each is connected to the corresponding sparkplug.

  Figure R

  Figure S

  
  

  Figure T

That completes the ignition upgrade. If no problems are encountered, this job can usually be done in about a half-hour.

RESOURCES :

Classic Car Restoration Guide: The Complete Illustrated Step-By-Step Manual
Model: 1850108900
Author: Lindsay Porter
Order this book from Amazon.com
Haynes Publishing

Classic Car Restorer's Handbook: Restoration Tips and Techniques for Owners and Restorers of Classic and Collectible Automobiles
1557881944
Jim Richardson
(November 1994)
To order this title from Amazon, click here.
H.P. Books

Thunderbird Restoration Guide, 1958-1966 (Motorbooks International Authentic Restoration Guides)
by William Wonder
Published by Motorbooks International, June 1997
ASIN: 0760303908
To order this book from Amazon.com, click here.

Illustrated Thunderbird Buyer's Guide (Motorbooks International Illustrated Buyer's Guide)
by Paul G. McLaughlin
Publisher: Motorbooks International (July 2000)
ASIN: 0879388706
To order this book from Amazon.com, click here.

T-birds.com
T-Birds.com
A website dedicated to the appreciation of 1961 through 1963 Ford Thunderbirds. Hard-to-find restoration parts and materials, including reconditioned original t-bird body parts, can be found through t-birds.com.

Vintage Thunderbird Club International
www.vintagethunderbirdclub.org
The Vintage Thunderbird Club International (VTCI) is an organization dedicated to the restoration of Thunderbirds and is an excellent resource for many aspects of restorations. The organization establishes juding rules and offers technical advice and production data.