Little bit more progress

This afternoon I managed to get out into the shed, it has been a while since I have managed to get some work done on the car and felt good.

I managed to finish off some of the shrink, both the front loom sections are complete with connectors installed with the exception of the front extended loom section.

The internal loom I have installed the center connectors and am in the process of pinning back out the ecu loom.
All the heat shrink is pretty much done but just have to label each section.

I have drilled the second hole for the loom but because the first hole is so large I am thinking of using a small backing plate to ensure it looks neat and tidy.

Pinning Out Connector

So after a little while with work taking up all of my days and into the night. This weekend we ducked up home to see Mum and Dad but I wanted to get some work done on the loom so took it along with me.
Managed to get both connectors nearly finished so just need to triple check everything with the multimeter to make sure I didnt put a pin in the wrong place.

HD30 Connectors

So far so good. This afternoon was spent pinning out the connectors and finalising some of the heat shrink.

More Heat Shrink arrived.

Needed to be a 150min order so got 6mtrs of 1/4, 3/8 & 1/8 sized HellermannTyton SE28 Mil Spec shrink as well as proper Mil spec connector boots that are adhesive lined as well.

Flex Fuel Sensor Arrived

If you are after a flex fuel sensor then highly recommend
"universelinkauto" as an ebayer. Cheap and the delivery was quick being just over 1 week from purchase.

Here is the sensor up close.

Loom progress

I have made some more progress on tue loom, this weekend was spent documenting each wire colour and connector as well as tue connector pin. Whilst I havent finished the aim is to allow easy trouble shooting should the need arise.
I also have started to put the motorsport heat shrink over the main section of the loom, because I wanted to test everything first this meant I had to remove the AMP connector and pins along with the Deutsch DTM and DT connectors,  it was a bit difficult bit I managed to get part the way there and then realised I had run out of heat shrink. Will have to order some more on Monday as well as some pin removal and insertion tool's for the Deutsch HD30 connector as I forgot to order them with the connectors.

Circular Connectors Arrived

Adding in some circular connectors through the firewall

They are Deutsch HD30 connectors, i was originally going to go with some of the exotic connectors but then would have had to buy another tool. These can use the tooling i have and are Mil Spec.

Here is the connector joined together, 

Ordered Flex Fuel Sensor

I ordered a flex fuel sensor to install so I can check the ethanol content of my fuel on the dash.
All up was $100delivered which is a lot cheaper then Haltech or Zeitronix are asking for them. I am going to pot the wires in and install onto a Deutsch DTM 3 pin connector.
Part Number is Continental Ethanol (Flex Fuel) Content Sensor 13577394.

Loom One Branch Complete with Comnectors

Loom branch one complete

Tonight I finished off branch one. This is the branch that goes under the plenum and across the front of the motor.
It holds the injectors, IACV, TPS, Intake Tmp, Knock, VTC, CAS, Boost, Water Tmp, Water Tmp Exit and a spare circuit for another sensor as well as a spare to run a crank trigger.
This means if I want to add something latter I can easily.

Loom Update.

Well after a couple of good weekends I have managed to crank the car over and test the wiring circuits.

I am still a while off finishing the wiring however am in the process of now removing the entire loom and covering it with motorsport military grade heat shrink (SE28, Raychem).

This was a step I took as I wanted to ensure everything worked before covering it all up.

With the wiring I had some issues early on with the ignition circuit and what I thought was a faulty ignitor but after purchasing another I worked out it was a grounding issue and quickly fixed.
Next I found I had the pins on the injectors and ignition around the wrong way as I thought the cylinders went 1234 from the firewall but its actually the other way around.

Following that I decided I wasnt going to run a crank and cam trigger just yet but I will leave the extra shielded wire in the loom just in case. As a result I had to rewire the shielded wires for the Nissan CAS.

Surface Rust (incorrect preparation)

I must not have prepared the paint well enough around where the roll cage was welded to the chassis as after 18mths it was showing some signs of rust coming through the paint.
Rather than leave it I took the opportunity to touch it up and sand tje affected areas right back, treat the surface and repaint.

Crimping

Photo of a crimp on a weatherpack connector.  Getting pretty good at this

We have power

This afternoon I managed to hook up and test the power circuit and Isolation switch. After a little trouble at first with the switch I swapped the cut out and on buttons over and it worked.
The dash, dl1, front lights and all the acc and engine power works.
Still lots more to do but this was an important and significant step in getting the car back on the track.

Power Isolation Switches

I have had some trouble finding large round NC and NO switches for the battery isolation on and off switches. I have gone with some simple square ones and had to paint one green.
I used some left over model paint which was the right colour.

Firewall/bulkhead power connector

Here is the connector fitted. I was in two minds if i should cover the main power wire from here to the isolation switch with the proper SE27 heat shrink but decided against it as it is not a very long run and not issues with water/fuel or abrasion.

Sorry for the poor photo as i was reaching over to take it

Power and Starter power wires

Almost finished the main power wires from the engine bay. Just need some clear heat shrink over the labels.

Wing Mounts

Here are some photos of the wing mounts.

And underneath,

Firewall Alternator Power Connector

This afternoon I was pretty happy with myself. After 2 weeks of doing nothing much aside from things to do with other then car i managed to get into the shed and watch the Wakefield 300 and then V8s whilst fiddling with the car.

I managed to get the Alternator firewall connector drilled and pretty much fitted as well as changing the rear of the power panel. I had to do this as after deciding to go with the Tyco isolation switch I needed to change the wiring around a bit.

Battery Isolation Switch Install

Tonight I started to install the battery isolation switch. I have decided to mount it on the transmission tunnel and use two Rivnut inserts to bolt it in with, the brass holes on the Tyco Kilovac ev200h are 5.5mm and I needed them to be 6mm for a M6 Rivnut so I drilled them out to 6mm.
I then added on a 2 pin deutsch dtm connector for the on and off switches to simply connect into. I have added in the two rivnuts and used hex m6 20mm bolts to secure it to the tunnel.

Deutsch Connectors

For the connectors for the wiring i am using Deutsch connectors. The are really nice but pricy although I found going direct to the Australian distributer they were very affordable. Much cheaper then I could even find in the states.

Here is some photos of the 12 pin connector being put together for the Race Technology DL1 and installing the pins for the connector using the proper crimp tool.

These are the pins

Re Wire, Re Started - Engine Loom

So after a fair while of doing nothing on the car I started to connect up some of the engine loom.

I bought all new connectors from online which has made it easier.