Had a truly Torrid time doing wiring today , making mistake after mistake ,lost count of the number of times i made a connection, assembled something ,then at the last minute it comes apart , but got a bit done ..
dip beam ..
looks about the right height surprisingly..
maIN BEAM ..
and all together now !
now to connect them to my remote fuse/relay box that i have taken apart and started labelling ...
since r-n-s forum has gone mental , i thought i would post a few of the last few weeks progress on here so i can pollinate twice as often ,and actually upload pictures that show !
OKEY dokey ma petit baguette's de lurvE !
a miniscule bit of fun in the cave yest and tod...
i created a fat podgy mutant fuse box ...
tucked in its svelte exterior ar 4 relays and 4 fuses for same ,one of them a 60 amp whopper to cater to the rediculous surge from my genetically enhanced radiator fans..
what ! don't ? believe? me ?!
have a butchers ...
yup packed with pert relay/fuse goodness.
now i have a 40 amp fan relay ,and 3 other relayed feeds for the headlight main beam , dip and fogs.
then i set too making a mount for em ... got an old bit of manky ally..
hacked it about a bit to make this ..
and the FB slide mount fits like so ..
and i then tiger sealed it to the chassis..
only to pop out to fit the box today to find the tiger seal has gone a bit heffner ,and got no sticking power , and it had all fallen off .pooh !
so i scraped it all off ,and siliconed it on there instead maybe that willl hold .
while that was setting AGAIN , i went round the back ,and extended and heat shrinked wires so they all measured the same ,and were ready for a plug fitting ..
so that's the job for tomorrow , oh i also ordered some 15w led reversing lights in a 22mm diameter , to fit in the corners by the thingmy duufah.
i realised today i had been putting my fingers in the flux and rubbing it on the wires , and stuff , and then read about zinc chloride ,what flux is made from , NOT very good for you to touch or particularly breath in ..so i started wearing my rubber gloves and not breathing ,,,that fixed it .
would you believe it , my YouTube channel ,for some reason best known to themselves , allowed monetisation ,and i just saw that , in theory, i have made a whopping NINE PENCE !!!!!
yup ! ,that's right ,count em ...that's nearly enough for um ,er, erm ,,, nope, i cannot think of anything that i can buy for 9p .......anyone ?
oh i know i can buy one of the screws for the body .
i was all a bit hmm what's the point when i look at the 10's of thousands of viewers the USA amateur car channels get , but now i am all up in their grill wiv de videoing innit ...again.
so every one rush over there and click on all the adverts you can find on my channel , and see if we can get another nine pence !!
ok ok ,hard sell over , back to the project ..
so last thrilling installment i was making my little brass plate , and the next thing to do was drill the dash with FOURTEEN MM holes .yup , big holes in my spanky dash , i was not really looking forward to making a hash of this, but ,needless to say , i did.
masking taped it all up , and drilled 4 4mm holes to start with ,not realising i was directly.in.line. with the poxy gauge mounting screw .
Tim off here and i were discussing this ,and decided there must be a word invented ,to describe that feeling when your all gung ho and do sometime on your car , and realise its very bad ,with horrible possible ramifications .... and get that prickling sweat, spontaneously break out on the forehead .
i quite like "Mienenfreude" , like "schadenfreude", but "owned" by the feeler ,if there actually is such a word then i am as usual just a bit late to the party.
"Gesvettenundpriklendasfurhedddisasterincommen" is a good one too.
so i now had 4 holes in my lovely varnished surface ,,in the wrong places .
i moved the plate so it just covered the holes , this brought me about 5mm westwards ,and by bodging and angle drilling like a barstard , i managed to drill the holes out to 14mm ,without constantly slipping down the original holes (much).
then i had a lie down .
then i mounted it all and it looked spanky..
buoyed by my success , i only went and drilled for the fan and pump warning lights too..
then made a little plinth for my last light ,
and that was all the lights done ,the finished assembly looked like this ..
yesterday i set to on the rear end wiring fun ...and i see this as pretty boring n of no interest , then it occured to my micro brain that others might be wiring ,and it might help to show what a hash i make of it .
so here we have the cable from the dash , a random salvaged plug , and the wires from the lights ...
soldered and taped plug to dash cable ..
used too much force stripping back the cables on the other half of the plug , and pulled a terminal right out ..BUM ...
found a 2 wire plug and adapted it , ,
all soldered and taped to the lights side ..
taped and shrouded ..
and tucked away neatly ,ignore the 2 loose wires ,those are for the reversing lights ..
wooof off i went to plug it into some power and admire my lighting , er, no, that will be two side lights on one side and two brake lights on the other , untape it agAIN , AND REWIRE........ STILL NOT RIGHT , THEN REALISE ONE OF THE LIGHTS HAS ITS BRASS TERMINALS IN THE WRONG PLACE , SO WILL INVESTIGATE THAT TODAY .oops caps .
Well today's mission , which i chose to accept , was fitting the brake light switch .
oh no wait i minute , i did a pre mission job first ,and that was to drill the chassis both sides by the lights , undo all the coverings again , and cut off the three, into two, into one, earth's i had done , and instead earthed them to the chassis at the back ... i was not happy with the possible 180 watts going down the earth lead diameter i had on there , so now its a lot safer .
got a bit of metal...
cut it about a bit and made the hole bigger ,
the switch is one of those that you ram in the hole, then give it a 90 degree twist , and the two ears that stick out retain it.
this meant i had to have two slots , so i used the same system i used when making the woodruff key slot on my fiat 16v head to A series block project , bottom pulley adaption ,with a hacksaw ..
that worked well, only thing is was the metal was too thick for full penetration ,so i ground it down from 4mm to 2.5mm... lovely jubbly.
Then i booofed off the tarry underseal this chassis is liblerally encapsulated in , and welded it on and painted it ..regardez !
jumped in the car with a multimeter across the switch, pressed the brake, and it blimmen worked...noice.
After that, i thought , lets have look at my speedo sender thingy ...and try to work out where to insert it .
in no time at all i had stolen a magnetic sender blob of another speedo , glued it to the rear wheel , and mounted the pickup like so..
hooked it all up to the speedo head , and with a long long lead to see if the signal would go far enough i span the rear wheel ,and got 11.7 mph out of it .briliiant , now i can have a tiny little bike speedo on the dash somewhere that goes to 186 mph , and not invade the general look.
then i started feeding leads through the chassis , rear lights , front lights, speedo, rear brake switch ,and pulled through and strapped em up loosely ...
after that lot ,theo and i felt like a bit of this ....
re wiring, i am in a indecisive dilemma about my sheathing choices ,i have had a few suggestions from readers , among which are ,
PHon Phaah ,a chap in tibet, pm'd me to say , he hand plaits tubing from the hair of 6 month old yak ,and offered to weave in a snakey design, using spun gold thread melted down from the inscriptions in a book written by the buddha whilst waiting for enlightement in the purple grove .
Angmar Philopedoneoson , in greece , suggested a combination of papyrus scrolls moistened and beaten to a paste , then mixed with ground stone ,made from the hitherto undiscovered missing Elgin marble , would bake up nicely in the cruciple left by Zeus on the slopes of mt Etna , and make a flameproof but flexible alternative .
Ooombah Mboombah , my new nigerian friend ,offered a material made from the third eyelids of the indigenous Anaconda, saying he would just have to go out and grab a few first ,oh and he wanted my account details for some strange reason .
And lastly ,and i think my favourite ,
Sven Svarglesonson , sent me a runic message ,no idea what THAT font is doing on this platform , and he suggested a tube woven from the hair of Brunehilda, who was some hot norse totty as far as i know , flailling around with axes and stuff and quaffing like a goodun ...and here's the thnig ,,apparently the quaffing stuff imparted amazing flexibility and tensile strength to the hair , and so it might be ideal .
There was one other offer ,a bit strange , from a bloke called NEO , something about picking the blue tube or the red tube , not quite sure what it was about , but he did have some cool glasses ,and a spanky girlfreind in skin tight leather .
until i make up my mind , i will stick with the cheap stuff , then maybe change later
well today was an up and down day , as the see saw tester used to say ..
on the plus side ,as you know, i now have my brake light switch in place and working , and my speedo drive working , front and back assemblies wired , switches and warning lights in , and saab relay accessed.
also i have tidied up the wiring to the brass heads..
from this ..
to this ..
and this ..
much neater .
i also re did all the wiring on the other side of the engines ,that feed the coils and stuff , so that's all tucked away neatly too.
then set too on the switch and light wiring ..
and i now have the two green lights coming on when i switch on the fans or the pump , also i made it so that if the fans thermostatic switch on the rad switches the fans on automatically, then the green light will come on too .
one last thing i need to do to bring everything to the dash , is the reversing light switch connection on the gearbox, so i hoicked the seat up ,and found the sensor , unfortunately it has a weird plug on it , so i took it out to see if i had anything to match it , while it was out i stuck the ohm meter across it and pressed the switch activation ball on the end ,.....
,bum , it doesna work , then i remembered i had a spare box , out into the car port , hoicked it out , whilst being buffeted by bees or wasps, think there may just be a nest out there ,and tested the other one , WHAT! , , it doesn't work either .
looked em up on ebay , darn, 8.90 , so unless anyone has a spare one lying around ,that works , i will have to fork out ! pooh.
here's what the blasted thing looks like , its off 1990 to 2000 sierra, scorpio ,granada, transit ...
and i am still stuck for the plug for the connection .
1) got the reversing light switch , cut it open with the thin disc , cleaned the ganky, corroded, spagged up, terminals and the copper disc that connects them up ,and then pressed/super glued it back together ,and it now works ,and is good and strong .
2)went all over the place trying to find the correct 4 pin hazard relay to go with my rover 100 hazard button , couldn't find one , so ,convinced of impending failure, i cobbled in a 3 pin one ,and worked out where all the 9 wires go off the hazard switch ,and connected them all up ,and stood back and pressed the button.....
......... and STUFF ME .... it worked ...as did the flashers .most surprising indeed . i do not have the flashers working with the yellow fogs on as well yet i may leave that till later .
..........i even made a vid of it!
3) on the down side, my saab dip/main relay is the wrong sort , but my good mate andy ,may have a saab 9000 one that will definitely do.
ok ok OK , i admit it , i had a bad attack of digression at the weekend , and i don't really know if its dead boring , but thought i would share anyway ...
now normally i don't work in the cave at the weekend,because i would just work all the time if i did and get myself all pooped out ,but in this case i wanted to fix my tvr , what blew a leaky radiator to hell n gone on the way back fro a local car event the week before .
i thought this would be a big job , removing the bonnt n stuff , but once jacked up( the car that is ,not me) i realised it would be possible to hoik it out with bonnet on ...grand .
i removed the intercooler ,and oil cooler out of the way ,and ground down the super rusted jub clips holding on the hoses , that have probably been untouched since 1992 , and dragged the sorry looking thing out of there , i luckily have another one given me years ago to put in .
this is where it all got a bit thingy..
thing is , when i have to just repair something , i allways want/need/have to ,make it better than it was before , and in this instance i was not happy with just the new rad , i wanted to do more .
so the intercooler went on the flowbench !!
this intercooler i made in 1989 , and i used a associated tarmac tractorv twin compressor intercoler , cut it down to fit ,and my friend Ian welded new ends on it , and in it went .
scrool forward to today, and after modifying my inlet manifold to flow 400 odd cfm instead of 300 ,here ..
i was thinking hey ,a nice 350 to 400 cfm on the intercooler would be great !
oh dear.... oh dear ......OH DEAR !
that's ,using my normal 150 cfm @ 28" pd per 100 bhp , about enough for 150 odd bhp , my v8 should make around 200-220 with no boost , so a big restriction .
i faffed about testing other ic's in case i could squeeze two in there ..
the top mount one looked alright but totally wrong for the space , so i set to with my biggun/low flow one , with deflectors n stuff to make it flow more ...
this had a couple of cfm effect , i tried a much shorter one but no better , so all i could do was to port the inner corner like so..
from this ...
to this ..
and that weazelled it up to this ...
so 165 bhp 's worth ...needless to say at some point i will find a better flowing ic , looking in the core of this one , the tubes are very small.
so then i spent a hot sunday putting the rads and ic all back in ,
and thank god it does not leak .
NOW BACK TO MEDUSA .
i now have the hazards working , and what's more Graham brought over the relay i needed to get the headlights working ,and it works a treat , so they are done too ,thank you GRAHAM !!
i just need to neaten and mount it all under the dash ...then its onto the reversing lights with my repaired switch ,and the lights for that came in the post this morning.
then rear fogs ,and i can put the cowl back together ,, oh a bit of eye candy may have occured , i fitted my button letters on.. have a look...
by the way i have tried using photo ucket just in case it works , its so much easier than having to put the img code around every picture one by one !
i managed the welt the drum off the back brake,with my big hammer , and found ..
yup ...no adjuster at all!
so i assumed the cable needed to be made shorter and so give me more of a pull, i could see the shoes moving a little as i pulled the lever , but not much , and obvioulsy not enough the work .
so made a spacer adjuster to fit in the adjuster hole like so ..
found a bolt the same size and thread as the cable adjuster , and a dome nut to weld to it ..
welded it on..
then i sliced the top off the dome, and tapped it through ,now the old adjuster can screw into it ,then i cut a slot lengthways in the bolt and the nuts i had , and it could then slide over the cable ,and fit in the adjuster hole in the chassis, then the old adjuster could simply screw into the back of it ..sits like so..
getting the cables back on was a trial , since i had made it as tight as possible , but got er done ,and now have some drag on the drum , but ,even with only three clicks available before it wont move, it's not enough , so i am now thinking, maybe the rod type handbrake mechanism has the wrong leverage ratio ?
research continues , if i cannot get it to work ,them a electric handbrake might be an option.
ok so now fairly up to date , heres the latest thrilling installment ..
Well , after a fair bit of retensioning it looks like the handbrake is a 'maybe' goer.. the mot chap reckoned i only need 16 % so i will see what happens on the machine , i cannot push the car with it on so that's promising !
in other news from the front ,
slight malfunction on the tvr front ..
so new uj arrived yesterday ,
on medusa ..
veronica gave me this ,from a load of stuff her stepfather had ,no idea what its off , ..
and i made this experiment ..
to use the cowls thus..
that's a speedo,painted black, and two dig temp gauges, one for each engine , and i have an idea to punk them up , by using projector headlight bowls ,and brass plate , may look naff but hey , worth a try .