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A few months ago I installed a GM headlight switch. The switch itself is fine but the small threaded part that connects it to the bezel turned out to be way too small. It was only holding on to both parts with maybe 2 threads each. After pulling the switch a few times it just fell out.

I made the part from an existing part (and instructions from Howard) that came with the GM switch. It has a really unique thread (7/16-28). You cannot buy a bolt with that thread anyplace. So I had to make my own.

I had to buy a tap and die and a 7/16 steel rod. It only took 3 tries to get it right. I think it cost me about $45 to make this little part. You can see the size difference in the image below.

One question for you folks. How are the tail lights grounded? I assume that grounding comes from the metal bulb casing but the tail housing that it fits into does not appear to be metallic. Am I crazy?

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My attachment screw must have been longer although I was careful to remove only the hex portion of the original. It extends out the same amount as the original so it can screw into the bezel full distance and still extends into the switch housing a fair distance. I had more trouble with getting the triangular shaft fitting the knob tightly than with the mounting to the dash.

As to the tail light ground, the bulbs do ground thru the socket shells which IIRC, is either crimped or held by push in socket prongs to the pot metal housing. 4 mounting studs screw into the housing and pass thru holes in the fender in spots sort of in the middle to lower third of housing. Ground is established to the entire tail light housing thru those studs and attaching nuts.

I have been so careful with these original sidelight lenses trying not to break them and then I bumped this one off the table today and broke off the corner of it.

I have a feeling these are not going to be easy to replace.

I have been working on the interior lighting and doors lately. It has been slow progress but it is coming together.

I have the interior dome lights working with the headlight switch and the door jamb switches. The headlights and tail & brake lights are working. I need to get all these done before the interior is completed.

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Those were in reproduction at one time and may still be. Dell posted that fact a few years ago so he might comment again or if not, you can try the name and number in this post to see if it is still active or if the lens is still a project. Tucson Packards may also have some as they sometimes carry repro items other vendors do not.

IIRC an early repro offering was a clear lens but don't believe that lens was entirely correct. Don't remember if that was due to the repro itself or because there was a difference between 55-6 lenses. Someone else came up with a milky white lens closer to what you show.

Depending on the quality you need, there are plenty of hazy fair condition ones floating around for cheap. If I were you I would go with a repro though probably.

Try Tucson Packards first, then Max Merritt as one or the other should have NOS lenses. Of course to match, you’ll need to get a pair. As for being milky, I’m sure that’s not how they were originally!

I'm sure Gerry at Packard Southwest has a pile of them for sale.

I have a new pair of lenses on the way from Gerry. I just assumed that a decent pair would be hard to find. Those exterior parts take a beating.

I have a question about these courtesy lights.

If I am reading the wiring image correctly. The light with 1 wire comes on with the tail lights and the one with 2 wires comes on anytime the dome lights are on. Is that correct?

I believe 55 works same as the 56 HT with main difference being they changed from 2 single function door switches in 55 to a single switch with dual function in 56.

Smaller single wire bulb does turn on with tail lights. Other bulb is larger and turns on when a front door opens. The doors also operate the interior courtesy lights but turning the interior lights on manually with the headlight sw turned to the left does not turn the outside light on.

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Perfect response from Howard. The only other thing to note is that the small bulb is grounded in the lamp, but the large is grounded thru the front door switches. If one is not lighting, troubleshoot accordingly.