small french hatchback

[davenport]

hello all..... been a bit quiet hey....

so errr....

i`ll keep this brief as tbh its not much to tell....

Pete over KAsensors sorted me out with 1 of his trick little air temp sensors, and Specialist Components have been sent the info to modify the ecu to deal with that...

Ive been working away over in Port Talbot on and off these past few months so made a detour to Dannys on the return trip while i had the van and collected my spit off him, that was then thrown into the powder coater at work and now wears a shiny coat of red!

after a bit (actaully a LOT!) of **Language**ing around Dave @ Satchells did the buisness and shortened a couple of shafts for me, these were then built up with new CVs both ends and new boots:

wheel speed trigger was refitted on assembly and i just need to make a new bracket to mount the hall effect (possibly off the 2 M7 Jbolts that hold the intermediate bearing in the housing):

 

[davenport]

over 30 months ago....

let me say that again,

OVER 30 MONTHS AGO..



let that sink in a minute... thats over TWO AND A HALF **Language**ING YEARS!!


over 30 months ago i tried to get the rattlebox wired, an easy task you may think (i did, originally) i mean, i approached all parties with the same brief -
make it work for 2 to 2.5k....

i got nothing other than lies and ********, i wont name names but if you read the blogs you`ll find out at least 1 of them, during that time my circumstance have changed, i`m now a dad and i`ve changed jobs.. TWICE!! and tbh these changes along with all the BS and delays came very very close to ending the project
but! i`m a persistant bugger, so, i went back to square 1.. i already knew of a few people, Simtek.. Si-leck.. viper.. tim mason.. but basically if you open up google and search "motorsport wiring" "motorsport harness manufacture" "motorsport loom" and write a list of all the UK places.. thats where i was..
probably only 50% of them got back to me, or at least replied with something other than, sorry, not our thing.. of those that did 99% of them either didn`t listen.. couldn`t house the car.. wanted me to make a mockup loom.. or wanted to sell me something i didn`t want!!

thru the project my dads been involved with:

i had gotten to know a guy called Clayton, clever bloke, (he works for a company called Parkinsons who make harness`s for various people ranging from the MoD to ginetta) and i liked the way he approached things.. so i got onto him and after a long chat he admitted the project was too big for him to work into his already busy schedule but his mate (boss) Sean was starting up a company and might be able to help..

Emails - texts - vists to the workshop - more Emails and we had a spec (kind of)

anything IN the car

thinwall pvc wire
raychem dr25 shrink
raychem transitions/boots
deutsch AS connectors

anything OUTSIDE

raychem 44 wire
raychem dr25 shrink
raychem transitions/boots
and a combination of deutsch AS and DT conectors
all ends tagged up with yellow ID markers..


the loom is broken down into a few "sections"
basically we have:

front lights+horn
engine+ancilliaries
dashboard (this will include fusebox/relaybox/ecu/dash2 controls/comms leads for ECU+DASH2)
main chassis
fuel system
rear lighting


its been a few weeks of working thru, finding details for ecu pin outs/speccing sensors (for which Peter @ KAsensors has been immense!!!) finding operating currents for all parts of the system but things have started to come together now:

to say i`m happy is a mild bloody unstatement...

a big big thankyou goes to Sean @ BespokeWiring and Peter @ KAsensors

sorry for the long winded (but not that detailed) update, but i`m actually happy with the actual progress on the wiring front!!!

 

[davenport]

Hello...

In between his day job/family holiday Seans managed to keep things progressing.. had a small issue of a deutsch crimping tool going missing in the post!! ££££££££!! But thats been sorted and hes sent over a few more piccies bless him..

I cannot begin to say how happy I am with it.. its everything I imagined and wanted.. cannot fault his service at all..

 

[davenport]

Aint done much tbh.. finding time is damn near impossible.. but.. started laying them out in the car and figured i needed a little bracket to mount the Souraiu AS connector:

fiddly little bugger as those bolts are M3x5mm

anyhow, got that made and fitted up:

Fuel harness all layed in:

Seans been over to measure up the final bits (engine harness and the 2 small bits that will power the front lights) he`s also took the dash complete to do that:

as you can see the fuel lines need pinning down, bit of an issue there, my cheap ebay nutsert tool decided to **** itself after 1.. ONE!!! nutsert, i wasn`t expecting it to provide a lifetime of service and be handed over to Jenson on my deathbed but i did expect a bit more than 1 poxy rivnut...

emails have been sent to the seller but i doubt i`ll get a refund.. probably easiest just to wrap it up in 1 of Jensons dirty nappies and post it back to them..

 

[davenport]

problem sorted with the rivnuts...

i borrowed the works gun:

and just incase i had access issues in tight spaces i made up a quick ghetto tool:

a few more hours today and i ticked off a couple of jobs that have been niggling me for a while:

4th engine mount:

painted and fitted:

and also the wheel speed sensor bracket:

fitted up:

also (if you follow him on FB you`ll have seen this but another little bit of loom is just about done for the passenger side front lights:

there will be another piece for the drivers side with an aditional spur for the horns, both of these pass thru the Apost under the wing and poke back out near each headlight so all out of sight

 

[davenport]

been throwing in those 4 sections today,
started off with the rear light section..
which plugged into the chassis harness up near the washer bottle:

and ran around the back of the car to feed the 2 rear lights and the 2 numberplate lights:

nothing however is that easy and to get the feeds thru the shell to inside the rear bumper i had to open out the small square holes to 20mm dia, find a suitable grommet, unpin the connector, thread the grommet on and then reassemble the terminal:

next job, fit in the Tpiece with the brake pressure switch which will activate the brake lights:

so far so good, the lengths on the wires were all pretty good..
to do the front light runs the wings were whipped off along with the wheels..
passenger side:

pretty hard for the phones camera to pick up but the pattern from the twisted raychem44 wire looks mega, all uniform and even:

the big ass hole in the passenger inner wing where the std loom passes thru will be welded up then a smaller dia 30mm hole put in for the grommet Sean fitted....

drivers side (30mm hole cut and grommet fitted)

lengths again all looked good, but this side also had the feeds for the horns:

wings back on, you can just about make out the deutsch DT connectors cable tied to the dash bar of the cage, theres 1 each side for the front light looms and another on the passenger side that runs down the car, these will all plug into the dash loom when that comes back....

http://img.photobucket.com/albums/v11/slammed106/20141026_134045_zpsmtveqmuu.jpg

 

[davenport]

the box of exhausts bits has been piling up over the past few weeks...

so, armed with a few sketchy measurements i set about laying a few things out:

a 2.25" bend was cut up to match that shape, and a piece of 2.5" tube was shrunk down to match up with it:

that was then thrown together with the Vband assembly Mike Edwards was kind enough to supply:

and along with some more bits all tacked up into something resembling what i need:

from here i need to make sure everything is right sizewise then strip it down, purge everything and tig it all up..

i`m still not 100% sure on the tailpipe.. i really like the idea of the downswept as i`ve used in the mockup.. if not it`ll be a plain straight piece of tube..

 

[Fergus]

Nice to see this back up and running!

 

[davenport]

Alright boys n girls???

Been bustin my nuts at work and spending some time with the family (yob has now hit 2 years old, gone mental quick).. but in between birthday cake and seemily everything i touch being adorned with bloody gruffalo images i got down the shop sunday evening..

casing needs shortening a bit and a big ol 45° slice taken off the top edge near the dampers.. but other than than i'm liking the looks of it

 

[davenport]

Evening all...

Been putting this off for a while now (i hate drilling spotwelds!)

next up.. more exhaust..

Purge gear setup

Leaves it all clean inside

Need to order some wadding and work out how to hang it..

 

[davenport]

Just a quicky..

Discovered there may be a small clearance issue with the bulkhead connector:

now, i wont name names as to who decided to put it there but its not where i'd asked and quite frankly there a thunder****!..

So i machined up some delrin blocks and clamped them tight against the bulkhead and hauled it up:

fingers crossed that'll sort it!!!

Threw the engine harness in, lengths all look good, still some bits to terminate/dr25 shrink but all in all mega chuffed:

and there ya have it..

2014 is just about done, so.. happy new year! In terms of the rattlebox it started off pretty **** with yet another let down on the wiring but has ended with a surge (albeit slow)

Have fun peeps

Mod edit: language

 

[af1]

errm

WOW!!

 

[davenport]

Halle-**Language**ing-luhah..

Exhaust - done..

Made a hanger:

Buzzed that on and filled the can:

finished up the centre pipe:

Penetration looked ok:

Fitted up:

And stuck the girl back on the floor:

 

[Cris B]

Now featured on http://www.build-threads.com

 

[lchris21]

awesome work on the Pug

thanks for the link to build threads....

 

[zx9]

Good progress Davenport, I had lost track of your posts some time in the autumn so lots of updates for me to read this morning.

 

[woody_02g40]

hope you don't mind it being submitted. The car will be amazing when it's finished, brilliant build right from the start.

 

[davenport]

I dont mind at all.. i'm flattered that someone thought it good enough to submit and also that the guys at BuildThreads agreed.. theres some mega stuff on there so to be with them is very very kind... all i know it was someone called Paul...

 

[woody_02g40]

Yeah, me! Well deserved mate.

 

[davenport]

Ahhh brilliant...

I owe you a massive THANKS, it was very kind of you...