Nova Research Project
Reged: 06/23/02
Posts: 508
Loc: Chesapeake, Virginia
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Hello,
Here is a short set of pictures that details the Nova TCS Switch, Wiring Gutter and the Rivets that fasten them together.
This first sections covers the small TCS switch 3961573. I do not have a large one yet. This style switch was interchanged with the larger 3983958 switch. I have not figured when they were switched or when or why they were screwed to the firewall. Click here to see the other attachements styles.
The first picture shows two OEM gutters compared to the two available reproductions. The reproductions do not have the holes punched in them. The holes can be punched with a leather punch, the same goes for the radio ground slot, just use a buckle punch.
Note the curve in the OEM gutters and the corners in the reproductions.
Here is a close up of the switch and the rivets. The switch on the left was media blasted and is bare metal. The one on the right is the original cad plating with the rust patina.
The left one was riveted in the holes exactly. The right one is the typical mispunched installation. Note the plastic still in the tubular rivet.
The switches are also date coded. The right one dated 12-9 was installed the 2nd week of January 1970.
Here are close ups of the OEM rivets and the replacement rivet and washer. the washer ID is a bit small and needs to be drilled out to fit on the rivet.
Here is a large picture of the TCS rivets and washers.
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Nova Research Project at chevynova.org
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mockingbird812
Reged: 06/04/04
Posts: 5748
Loc: Puh-hone-icks ('Buckeye' born ...
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Greg,
Here are some photos of my TCS fuse set up and wire gutter. Disregard the horn relay in the lower right of this photo .....
 
I'll reinstall this TCS fuse with Greg's rivets, washers, and special tool to a better condition wire gutter as compared to my original wire gutter. Case is at local platers for zinc finish to replicate original cadmium plating.
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Sam
Fire all of yer guns at once and...
explode into space!
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Nova Research Project
Reged: 06/23/02
Posts: 508
Loc: Chesapeake, Virginia
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The holes across the top are the following sizes.
3/16" x 5/15" for mounting to the firewall.
The slot for the radio hood ground is 1/4" x 1/2"
The switch mounting holes are 1/4" in diameter. Punched 1 1/8" on center a part.
The left set are 7/8" from edge to center.
The Right set are 2" from edge to center.
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Nova Research Project at chevynova.org
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Nova Research Project
Reged: 06/23/02
Posts: 508
Loc: Chesapeake, Virginia
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Here is a look at the plastic clips used to attach the relay. This was an early model year usage. Probably from start in July until possibly around December.
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Nova Research Project at chevynova.org
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CamarosRus
Pooh-Bah
Reged: 04/24/00
Posts: 1776
Loc: Renton(Seattle),WA USA
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Love this thread...........but respectfully disagree with CADMIUM plating as being OEM.
I cant prove anything, but my misc readings indicate that ZINC plating would have been used on these misc components.
CADMIUM may be a better choice for resto.........please share YOUR thoughts
regards
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Chuck Sharin
Metro Seattle
70 Camaro R/S Z-28, L-78, R/S SS
69 Camaro COPO "recreation"
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mockingbird812
Reged: 06/04/04
Posts: 5748
Loc: Puh-hone-icks ('Buckeye' born ...
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Chuck - I only mention cadmium as that is what the plater told me the original plating on my TCS fuse box looked like to him. 
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Sam
Fire all of yer guns at once and...
explode into space!
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mockingbird812
Reged: 06/04/04
Posts: 5748
Loc: Puh-hone-icks ('Buckeye' born ...
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Moderator - please make this a "sticky" topic.
Thanks!
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Sam
Fire all of yer guns at once and...
explode into space!
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mbxlesney
enthusiast
Reged: 03/02/02
Posts: 217
Loc: Ocala FL
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Hi Greg .....Just a note to let you know that I have sent you out $ so I can get 2 of your rivets/washers and I hope Im not too late. Thanks for all of your help in the Nova hobby!!!!
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Kim
1970 Nova Fathom Blue L78 M21 3:55
1970 Nova Classic White 454HO THM400 4:10
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Nova Research Project
Reged: 06/23/02
Posts: 508
Loc: Chesapeake, Virginia
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No problem, They should go out this week.
Greg
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Nova Research Project at chevynova.org
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mockingbird812
Reged: 06/04/04
Posts: 5748
Loc: Puh-hone-icks ('Buckeye' born ...
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Got Greg's rivets, washers, and tool the other day and I installed them according to provided instructions onto my "new" gutter that M22 Mike (Angelo) provided  . The only deviation I made was I found thinner washers which matched my originals that I took off of the Deuce. 1st photo shows Greg's rivet tool, rivets, and washers along with my original rivets and washers and also Greg provided a this-is-what-it-should-look-like-after-you-install-it rivet which was a nice touch. Greg's washers, as well as the substitutes I used, had to be drilled out to fit the new rivets and match the opening diameter of the originals. I am impressed with this kit and would recommend it. Well done Greg!
I used the punch (black) in this photo to make the two holes in my '69 wire gutter here and on the opposite side as that is the way they came from the factory (and matched my original gutter)
I slightly splayed the opening of the rivet with a punch to get it started as per Greg's instructions. I then placed a tool handle behind the rivet (inside the gutter) to provide a solid surface to hammer the rivet tool against. The rivets formed just as they should and it was really pretty easy. 
...and back in the car.
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Sam
Fire all of yer guns at once and...
explode into space!
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