Time for my second post regarding door ajar switches. Unfortunately, this may or may not be my last one on the subject.

Right now, I'm at a loss here with the door ajar switch for this '73. None of the new switches seem to be a perfect match for the original.

Left switch - '74 repo
Center - Original '73 switch removed from car
Right - '73 repo (first repair attempt)


The terminals on the '74 switch seem to be a match for the original, but it definitely sits taller. To me, it looks a little funny. Every time I even think about fixing this issue my paint chips a little more, so I'm really hoping for this trail-and-error process to end soon.


A little tape on the door...


A little sharpy on the contact...


Let see if we can sort out how this is going to work.


Despite everything, that really fit better than I hoped. The contact seems to be hitting right where it's supposed to, and it's not binding or doing any damage to itself or the door.


The switch seems secure for now; it's not loose or moving around, but there is a void by the top rivet where the original fiberglass looks rooted away. I didn't do this damage, so there's probably more history here with this switch that I'm not privy to.

Anybody have any repair tips for filling this spot?


The door closes OK (as well as it ever has). Maybe with a little touch-up paint this issue is fixed?

 

I feel like I've been waiting on parts for over a month. Actually, that's because I placed my order on 02/14/26.

While I wait, I decided that I would figure out these exhaust tips once and for all. As I mentioned in a previous post, this car is a '73, with a 2-1/2" custom exhaust made for a '72. While the main pipes are 2-1/2", the pipes exiting the muffler are only 2-1/4", which doesn't leave a lot of options for aftermarket tips.

These are 2" aftermarket exhaust tips. They're pretty cheap, for a reason.


At 2", these tips are just not going to fit the muffler pipes.


To fit the muffler, I'm going to need to be just over 2-1/4".


Looks like I need to break out the pipe extender. This kit gets more use than I would have ever imagined.


I'm using a 2" exhaust clamp to hold these in a shop vice. This is the easiest way to do this that I know. There's a welding glove underneath, just to keep the tips from getting scratched.


The smallest expander is too small; the next size is just a little too big. A little love tap should get this expander into place.


Looks like job for my air impact and a 1-1/8" socket.


Brrrr goes the impact wrench, and we've got a wider pipe now.


Just slightly over 2-1/4" inch should be fine.


My measurements are sloppy today, but this should be fine.


A little polish and everything is almost as good as new. Fortunately, there's very few marks on the tips, considering how much they just went through. Any blemishes won't be visible once installed.


Left side installed. I had to get creative with my brackets, but it's all good.


Right side almost installed. Again, the brackets were tricky, but I was undeterred.


Project complete. I think this is honestly about as good as it will get, so I'm calling this job done.

 

I'd probably spray that entire back plate around the hole, flat black so you don't see the round hole, that way it will look like one big opening. Whata ya think ?

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Nicely done!

 

Or is that all dirt / carbon ?

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