Thursday 15 January 2009

Cracking on & Boot lid wiring

Christmas and new year a distant memory now.

I was planning on ordering the chassis early Feb. But things haven't quite worked out with funds just yet. Never mind for now.

I have been busy tying up loose ends.

Pedal box was removed, to drill hole and slot to accept the throttle cable in the pedal.
Not the easiest thing to remove and reinstall by yourself. Bolts in footwell, nuts behind bulkhead wheel arch.

Next, Rear number plate light wiring. This is supposed to feed through the boot lid and hinge. I firstly decided to cut the loom in the boot and add spade connectors to both ends. This gave me about 1.5m to play with trying to get it through the boot lid and also enables the boot to be removed at a later date by disconnecting the loom.
Getting the cable in was a little tricky. Managed to get a pilot wire through eventually, but then found the main loon a little bigger than the space in the boot skin. Eventually got it through by smearing cable with grease and soldering the pilot wire to the 3 wires in the loom. I then realised that I still had to go through the hinge but had crimped that end with spade's. oh well, cut crimps, thread cable through hinge and crimp on new ones.

Fitted the boot lock with nylock nuts behind M5 screws rather than self tappers. I just felt the boot would be a little more secure.

Fitting the boot, took a while as the shut lines needed adjusting as one side the gap was 2mm opposed to 8mm the other. This unfortunately meant I had to remove the hinges and open up both sets of 4 bold holes to enable more adjustment. Snip the crimps again. Good job there is plenty of wire! :)
All fitted a few hours later. Once set It came off for the last time..... (Going to regret saying that) for final polishing. (saying that too)

Next day I decided to fit the boot support stay. I would have preferred to go with gas rams, but the standard lock stays are sufficient enough for the little use they get and thinking about it, they wont be forcing against the body all the time like gas struts would but gas struts do look good. Got some brackets made up, had to bend them to shape and drill.... bosh... done.

No comments: