I suspect I will get a lot of different responses for this, but I would like any input as to exactly where and how to make a hole in the splash apron for my 09 Touring to accommodate the Rubber hose from the Generator.

First of all, you are talking about the SPLASH SHIELD! I could have helped you a couple of months ago when I had my rh splash shield off. It's pretty hard to do without one right in front of me, but the hole is straight down from the speedometer, and is about 1 1/8" diameter. We make the reproduction grommets, and made them from a NOS original I have.

Daniel, I have seen past posts with measurements for the hole in the splash apron but a quick search didn't find them. Possibly others who are better at searches can post a link for you

Daniel, This might help.

http://www.mtfca.com/discus/messages/708324/790631.html?1505838488

If you have a friend or acquaintance who is an electrician he may have a knock out cutter used to punch holes in electrical panels. Even better if he has one that is an 1-1/8 inch.

According to Gail Rodda's booklet (Vol. 3, page34) on the production 1909, that hole in the shield for the rubber hose was punched, with folded under edges to provide a smooth entry for the hose. A simple cut hole would chafe the hose.

I have had good luck and good end results by placing duct tape over the area where you want the hole. Be sure the tape coverage is much larger than the hole. You can then drill thru the tape without the drill skidding as well as protect the paint in the process.

close up of 1909 hose in shield.





This underside photo is from a 1911, but shows the factory way of up-setting the punched hole with some sort of fixture to fold under the sharp de-formed metal from punching.



The hole on this 1911 was on the flat of the shield, an earlier shield would have the hole up mid way or so on the shield.

Generators or acetylene tanks were optional equipment on the early T's so that hole could be most anywhere on the early ones prior to the lamps being standard equipment.

When I did the faux '09 runabout, used a PrestOLite tank, and found a cute brass fitting with angled flange and used that to route the rubber hose. Of course the fitting was just a dead end. The lamps were electrified from the storage battery, as the faux '09 had '23 engine with starter and generator

I have seen 1909 shipping invoices which show that headlamps were installed prior to the car being shipped from the factory. That would lead one to conclude they most likely were put on at the factory by customer request and that Ford had some standard by which they made the hole. It also is quite possible that some were put on by the dealers who may have mounted them and put the hole through the splash apron where they saw fit. I believe by 1910 that headlamps were standard, and the installation procedure most certainly was done at the factory under some SOP. Logically, if we could see enough examples from original cars, we might better know how Ford did it.

Thanks Dan for sending those two examples, but if we could see more original 1909-1910 photos or modern photos of original cars it would be a big help to know better where and how the holes were made. Hopefully, some more Forum members will post some additional photos.

Daniel

True that many were equipped with generators and some with PrestOLite tanks too.

But any factory mounting depended on the brand of generator, as they each had different brackets to mount, and each had gas outlets at different places. So do doubt that Ford had specific written instructions, let the mechanic/assembler do that job. Those early years it was lot of assemblers without an assembly line like in later years.

Here are some more photos, different hose locations and different generator versions and mounts.

I just noticed the cowl lamps on the next to last photo Dan posted above of a couple in a tourabout.

They appear to be the rather rare Indiana Lamp Company kerosene lamp supplied on some early '09 cars.



Ken in Texas