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Reply to "Maui garage find Intermeccanica rebuild"

Hard part: Bosch ignition switch 644 613 101 06

This switch is great. The keys are large and give you enough torque to easily go through the switch positions.  Positions are: ACC, off, on and start. Interestingly, you can't just turn all the way right to engage the starter. You have to push the key in while turning right to start. Nice safety for banging up the starter and flywheel while the engine is running.

So why was it hard? The old switch just used a round hole and you torqued the bezel down to keep it from spinning. This new switch uses the same diameter hole, but there are six threaded protrusions that engage the dashboard to keep the switch from spinning when you turn the key. You have to cut out six little gaps so the new switch can fit into the dash. 

Tip: the key is set up with the wide part at the bottom and the teeth at the top. That means it looks best when the switch is installed upside down. Many cars have the ignition key teeth on the bottom. I think this one is best set up with the teeth upwards.

I placed the switch over the old hole and used a pencil mark the areas that needed to be cut out. I used a Dremel tool with a small cutting bit to work my way around the perimeter and periodically tried to insert the switch from the front. I could see where it needed more relief and marked those spots with pencil and then used the Dremel again. Towards the end, I started putting the switch in from behind the dash and focussed on keeping the key slot vertical (and oriented so the key would be teeth up).origIGN

Original ignition switch hole

IGNdremel

Making the cutouts to fit the new switch

IGNSwitch

The new switch

IGNsw1

And it finally fits. Note the orientation of the key slot

IGNsw2

Nearly ready to start the engine (if the body was attached to the chassis :-)

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Images (5)
  • IGNdremel
  • IGNsw1
  • IGNsw2
  • origIGN
  • IGNSwitch
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