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The next day I poked about and found that the main wire from the fan to the accessories pole on the ignition had fried big time and melted two nearby wires with it. The accessories pole had overheated and burnt the main wire too.
I cut it all out, broke out the soldering iron and replaced it all.
Then my buddy MeltedCheese came round to help find the cause of the short - unhappy with the fact the fan was kicking in when it shouldn't (I assumed it was literally because a wire must be shorting) he Googled some relay wiring diagrams and realised I'd been a melon and hooked it up wrong.
So with that sorted, the wires once again performed their duty of keeping all the smoke and magic on the INSIDE of the insulation.
However, it didn't start any more.
A quick tip of the fusebox and the pump would prime, it was as if I was turning the key on and off. So there was clearly a dodgy connection between the ignition switch and 12v at the fusebox. Stripped wires left right and centre and couldn't find a problem. Then I realised that a 25a box fuse had popped but the filament was flapping about and occasionally connecting causing it to re-prime etc.. I replaced it and it started up! Didn't want to run it in the garage so I shut it off, went out and moved the Cav out of the way and jumped back in the Capri. Nope. Fuse gone again.
So, at the moment - the 'Engine Cont' 25amp fuse is popping. Unfortunately I'm back at work on Monday and the progress is once again going to be hit on the head. Yet again, the car is achingly close to the road, and abandoned in a state of disrepair!! This car is.. how can I put this?... er..
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Aug 30, 2014 10:11:23 GMT
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 If you ever see this car at a show, you should appreciate that it will be a very rare moment in time and you will be one of the lucky few to have ever seen it out of it's natural habitat (broken, in the garage). |
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Does anyone have any genius cheap ideas for loom wrap? Spent days unravelling sticky minging insulation tape from the whole loom. The wires are all a sticky mess - I bought a roll of self amalgamating tape and its great but I'd need about 50 rolls to wrap the entire loom and this is a budget build. Looked online at loom wrap thinking the internal diameter would be irrelevant as it just spirals around the wiring but every listing quotes the internal diameter. I have wiring that ranges from 3mm to about 70mm!
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MrSpeedy
East Midlands
www.vintagediesels.co.uk
Posts: 4,791 
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I just use this stuff for pretty much everything  It will wrap a lot bigger than the stated diameter, but if you have that much variation then two or three sizes would make it neater. With a bit of practice you can make the joints invisible |
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Last Edit: Sept 9, 2014 8:42:51 GMT by MrSpeedy
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Sept 9, 2014 19:41:10 GMT
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Thanks guys, I'd guesstimate that I'll need about 30' of the stuff annoyingly. I will never make the mistake of using insulation tape to wrap a loom again!
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Any updates on this? It looks like an awesome job you've done!
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As a matter of fact there has been some progress. We basically stripped every bit of tape or loom wrap off the entire electrical system and worked through every wire individually. We've repaired or replaced any suspect ones and ripped out anything not needed (two carrier bags full!). In the process we found out that the lambda was never receiving 12v due to the wire being snipped for some reason - neither was the ACC valve! Neither of which can have been helping the running issues!
Got it all back together yesterday after another full day on the wiring. Turned key and away she ran! Spat out plumes of white smoke for about a minute but we've put that down to lots of condensation and general curse word in the exhaust as we had it idling for 30 minutes to check the leccy fan cycle and all was well. Apart from a tick on the down pipe it ran beautifully. In the process of sorting it, it's become a bit of a function over form car. The dash was kinda wrecked when the wiring overheated which didn't help, but I had bought a replacement. I went to fit it and had second thoughts. I've ended up cable tieing and bolting gauges and switches to the dash frame rather than fit the dash. Bit of a different look shall we say, but I'm just trying to get the thing going and mot'd - big plans in February!
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Yes this really has been as fun as it looks  Here's my mate working through the driver's side gremlins as I did the passenger side...  |
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It's now looking better than this by the way! When I've had another day armed with the cable ties I'll take more pics - it hasn't exactly got the luxury feel the interior used to have but hey, it works!
Edit: the radiators not bent, it's a panoramic pic!
So, I need to:
Clip up rest of loom.
Mount dials (Nissan cluster).
Free off rear brakes.
Fit new hazard switch.
Get washers working (again).
mot
tax
insure
Massive curse word burnout.
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Excellent news! So glad that this will be back out soon - it could have been so much worse.
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Living the dream. Restore's classic car's for a living!
Project Racer: '99 Arosa
Project Touge Outlaw: '87 Porsche 924S
Project Street sleeper: '95 BMW E34 540i/A Touring
Project Mafia: '04 BMW E53 3.0d
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It definitely could have been a lot worse! Just waiting for a free day to finish the electrics and then I'll book an MoT.
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Jan 18, 2015 10:33:51 GMT
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Wish me luck chaps, a free afternoon has presented itself. I'm going into the garage armed with a pack of cable ties, a mallet and some determination! I'll update with progress later
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Jan 18, 2015 10:53:22 GMT
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just read from start to finish, very cool project! stick with it!
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Cheers bud  Well, that was a successful afternoon's play! I fear that the weight saved by ditching two bags of wiring has been replaced with the weight of 2000 cable ties but I'm happy with the organisation of the wiring. Some sections are unavoidably ugly and bunched unfortunately but on the whole it makes sense and is nice and organised. It will need wrapping in the near future though. The only things I need now for an attempted MoT are: Washer pump Earth wire on speedo handbrake adjustment/rear brakes freeing. Had her up and running until it hit 95 degrees, leccy fan came on and cooled it appropriately and continued the cycle. Bit of a blow from turbo elbow (missing a nut due to the angle of the down pipe) but other than that, sounded well. It needs the base idle adjusting at some point, due to messing about with it trying to get it to run right (there was never power going to the sensors!) but really, that's a minor thing. Have to say, it's not quite the plush carpet (although carpet's still there - mostly), suede-dash show car that got photographed for the magazine, but I am enjoying the 'cable tie sans dash necessity' look. |
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Ian
Part of things
Posts: 977
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Great news Dave, weather on the wirral yesterday was rather unpleasant at times! By the way I spotted Unleaded at Asda Queesnferry yesterday at 97.9p per litre might help the running costs!
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It was blooming freezing! Struggled to form words when I got in! Good spot on the fuel  Phoned up to try and insure it yesterday, it'll be a 2nd car with limited mileage, my mk1 cavalier being the daily. Can anyone recommend a company likely to offer a good deal for this scenario? Only one will be able to be garaged. My current company sounded very confused when I reeled off the mods and then called back to say no can do. I need both cars insured so it's gonna have to be a good deal. |
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Jan 21, 2015 16:23:49 GMT
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Any pictures of this dash then?
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96 E320 W210 Wafter - on 18" split Mono's - Sold :-(
10 Kia Ceed Sportwagon - Our new daily
03 Import Forester STi - Sold
98 W140 CL500 AMG - Brutal weekend bruiser! Sold :-(
99 E240 S210 Barge - Now sold
02 Accord 2.0SE - wife's old daily - gone in PX
88 P100 2.9efi Custom - Sold
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Jan 21, 2015 22:22:48 GMT
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I'll get some at the weekend - it ain't pretty like! Hoping I won't have any mot issues with it? Got a half decent quote from the boys at brentacre too.
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Jan 25, 2015 23:08:29 GMT
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Good news! I'd ordered a new washer pump but it's failed to arrive. I decided to see what was up with the one I fitted. Took it apart and one of the plastic pulleys was jammed solid. Freed it up, oiled the gears and jobs a goodun - we have washers. Which means it's ready for an MoT. Going to get it down this week some time fingers crossed. Cavalier isn't happy at the moment either, so this could take over daily duties for a bit if all goes to plan. Pic of curse word dash as requested!  Not quite as nice as the previous incarnation, but it serves a purpose! It's functional and neat, and in that, it gains some aesthetic quality somehow. I suppose! |
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