Re: ‘37 model 78 horn problem
You don't mention grounding which I think is the problem but your test results are puzzling. The 37 Ford horns have two leads; one is connected to the battery (solenoid terminal) and the other to the horn button for grounding when the horn button pushed. The horns are not very accessible.
When you connect them to the battery, they blast away. Well, they shouldn't unless you ground the other wire in some fashion. Do you press the horn button in this test? If not how do you ground the other terminal? I would think if you grounded it through the horn button, you should get the same click which means the horn ground is inadequate.
Without the external 6 volts applied, you should have 6 volts on one terminal. If you press the horn button and the voltage does not drop, then it is providing enough current. Then with the horn still depressed, check the voltage on the "ground" side of the horn. It should be near zero. If not the horn ground is not adequate. Look at the horn ground and clean up any corrosion (which could be at the bottom of the steering gear)
Ford had a better idea for 1938 by having a relay deliver 6 volts to a single wire horn and grounding the horn to the frame. You could do the same with your 2 wire horn if having trouble cleaning up all the connections.
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