got the battery in, the surge tank in, the pumps in, the filter in, some of them hooked up, the front ally panel in, the driveshaft in, and tidied all of my tools. this allowed me to move the truck back and fwd and clean under it...
i'm going to make a more solid start tomorrow evening and try to get a few things ironed out and finished.
no pics tonight. added the nordlock washers to the fuel components mounting points, torqued them down, mounted all the fuel lines to the cab, added a million hose clamps, cut various bits of hose to go beneath them, installed and drilled the rhs ally cover for the fuel box put everything away afterwards!! very unlike me. and devised a plan to keep some random little girl happy....
ie, not kill her [fizzle]ing little piece of [shizzle] cat that keeps spraying its "scent" onto my nicely painted chassis. instead of finding and killing this cat (which may not have been easy) i decided to crack out a second tarp and totally wrap the whole thing down to the ground. i laid pieces of wood on top around the edges to stop the little buggers wiggling under to do their thing....
progress is slow on the details...
will be good to finish the whole back half soon though
ok, tonight i got busy and got quite a bit done. lots more to do tomorrow though.
i realised this morning that the work i am doing at the moment is no use to me. i'll invoice on the 31st may, and wont get paid till i've been in the UK for 2 weeks. so, i might just give up work, and become a full time truck worker on er er
tonight :
fuel lines in for good, all hose clamps in place, all P clips secured with one s/s button headed screw and nylock nut, and two big cable ties. some ppl may think i'm paranoid (like my auto sparky when i told him i wanted to fuse the power wire from the battery to the starter) but i just love cable ties!! :-) anyone who i've done car stereo work for will confirm that ;-)
fitted the filler cap to the deck with s/s csk screws and T nuts
fitted a carb pump to prime this system before trying it.
made the fuel filler pipe up.
cat proofed the ute again.
by the end of tomorrow, i want all rear wiring complete, and the fuel system tested. if theres any time left, i'll get back to the wastegate and exhaust. once thats done, i can put the ply on for good! cant wait for that moment.
pics including my trusty assistant sleeping on the job, literally :
and last, but not least :-)
bear in mind, its about 1am... and shes out helping her man on his ute :-)
ok, so yesterday i filled it with 98, hooked up the little carb pump and primed it ....
WOOOOOPS
the drain fitting in the bottom of the fuel filter was wide open.... fuel everywhere... paint disolving... bugger.
alas, when the fuel dried, it wasnt too bad.
after solving the massive gaping hole leak by doing up the knob, i finished priming it, waited for the surge tank to be fullish, then removed the little pump, and fired up the 910. works well, as expected and designed, creates a little pressure in the surge tank ~ 1psi, thanks to the 1/4 out back to the main tank. so then i hooked up the 044 and primed the main line fwd with it, and then the regulator and initially had it in backwards (silly mistake indeed)
after reversing it, it was sweet. held steady pressure of whatever i chose from 5psi to 100psi (not brave enough to go further).
cool thing being that you can hear the flow, and the 044 keeps hammering away even at such high pressures.
zero leaks in it, and everything is rosey.
added a complex emissions system involving two hoses going up and pointing down! :-)
also did some wiring/planning
crimped on connectors for the fuel pumps with a proper tool may revisit and solder at some point also. made up the lead from the battery term to the circuit breaker. drilled a bunch of holes to allow thing to be mounted and get in and out of the box. designed the layout of the relays and bus bars and fuses etc.
pics
^ fire faulty! FIRE ;-)
thats all folks.
i intend to finish the wiring today, but i am misisng a few screws etc. i should be able to get it mostly done...
ok, so i got it mostly done. only the 7 core to run from the original loom, and the main battery feed etc cables down the other side. then the muffler welded up, and the deck can go on for good.
wired up all the relays etc with the lifted ground rear light cut circuit
drilled all the holes to let all the tail light wires in, soldered in all the tail light wires, and routed them with cable ties. slow going, but satisfying in the end.
i got a bit done last night, but had to pack it in feeling so tired that half way through soldering a cable i nearly fell asleep. went to bed at 12, about 1 - 2 hours earlier than usual. the weekends slow progress and the fact that any pay i recieve now is a bit late in the piece to be useful contributed to the fact that i called it quits at work on monday. i told them friday was the last day. it surprisingly caused quite a stir. its all settled now, and it looks like i may even not be needed on friday. we will see. up shot is that i will be FULL TIME on the ute soon. if you think 4 days notice is too small... its not really, they know i'm going away, and all my contracts have had a 1 day notice period in them for both parties. i thought that was a bit harsh, but now its quite useful. so, i'm looking forward to working on it during the day with non cold air and some better lighting. i'm also going to sleep in on the first day not at work. seems like a good idea. i've had no more than 5 hours sleep for a couple of months. perhaps last nights performance problems were a build up being exposed. i also noticed last night that i have lost 3kg (7lb) in the last 1 - 2 months of flogging myself over this project.
thats not to say i wont keep flogging myself... but something had to go, so work lost. as it should be in my books. i'm back to the happy unemployed bum life i lived for years before this job started in may a year ago. ahhhh the simple life.
photos from last night were simple and ill conceived, not to mention of half finished work. just a couple of cables going into the cab....
tomorrow night i'll do that. tonight will be that outstanding ms work, and an early night. possibly a birthday treat too ;-) other than the roast and desert :-)
the ute project took another hit last night... as a special birthday surprise, my laptops hard disk crashed. great. being a software developer, i kinda need the machine working... so had to spend all of today (still going, started at 7:30am, now 6pm, and will be here for a while) recovering my files to a new external usb drive (320g) and when thats done, fun oh fun, i'll have to reinstall my precious debian on the new NON FUJITSU seagate 2.5 160 5400 ide disk. great fun i tell you.... almost as good as getting s/s grindings in your eye while upside down under a ute with no time to stop and relax. hooray. just my luck....
enough whinging... on with the loner install fest.
the other side is all hooked up and i have to say, i will NEVER have to not see while reversing again :-)
there is one little issue though, the lifted ground that the relays are on is pulled low by the indicators back feeding to ground through the bulbs and power feed line when its not held high.
solutions :
a diode in each indicator line rearward
a relay for each behind the seat that isolates the rear indicators from the front when powered off
not keen to put a semiconductor in the line to the trailor plug, as they are not fault tolerant, and trailers are an external system...
if i put a relay, i need to run a ground to there, not too big a deal as i need to run one there anyway for the fuel sender unit whos ground at the rear disappeared with the redesign. i think powering the coil and feed pins of the relay will work well enough, though there may be issues with the kick back when turned off powering itself, will have to think about it.
tail lights look mint :-)
i'll snap a pic and post it while i think about the indicator back feed solution.
fred.
wiring info for prosperity :
trailer colours :
brown = tail
green = rhs indicator
yellow = lhs indicator
red = stop
black = ground
fuel guage sender :
yellow to copper to yellow to dash via factory loom
black to tinned to ground via wires along trans tunnel
main loom to the back :
my wire :
yellow = lhs indicator
green = rhs indicator
red = stop
white = tail and number plate light
brown = reverse (from 3 way switch on dash for on,off,reverse)
black = ground lift trigger (from switch on dash)
blue = fuel pump trigger (from ms)
factory colours rear side of the plug :
base colour/longitudinal colour/radial colour/function
red/blue/NA/tail-npl
red/pale blue/blue/??? (could make it go on, but didnt test for grounded or not)
yellow/NA/NA/fuel guage signal
green/black/red/lhs indicator
white/green/red/stop
green/white/red/rhs indicator
red/black/darkblueORblack/tail-npl
red/white/blue/reverse
white/blue/red/stock in tank pump power line (grounded to chassis further back in stock form, just like fuel guage sender)
wires to the tail lights :
blue = tail
green/yellow = floating earth
brown = stop
all other rear two core lines red = power and black = lifted ground.
50mm sq cable lhs/rear entry = ground
50mm sq cable rhs/front entry = main feed to starter and ute electrics
8ga dse cable lhs = alternator charge lead
8ga dse cable rhs = ms power feed
small red wire on lhs = alternator voltage ref brought to the back to ensure that the battery is kept at 14.4v rather than some other point in the wiring.
relays from lhs of car to rhs :
ground lift
reverse
tail
stop
bosch 910
bosch 044
cant lose this info now ;-)
Last edited by fredio54 : 5-12-07 at 18:57.
Reason: store wiring information without new post...
just tail lights (brake are a lot brighter as they should be) :
with hazard lights on :
with reversing lights on!! :
thats the last work rear of the cab to be done with the following exceptions :
the last half of the exhaust which i'll tack tomorrow morning so that i can put on the plywood for good.
the towbar that i'll do later.
the side/tail boards that i might do later if its running soon enough.
kinda exciting, only intercooler mounts and plumbing, intake mani, megasquirt wiring, exhaust finishing, and tuning to go!!
i'd better buy some adult nappies when i get it running.
i just took it out onto the road to turn it around for exhaust work, and with one front next to the curb, and the other next to the drive entry, one rear on the grass, and the other on dry concrete, it just spun both instead of backing over it. and thats with half my tools on the back!!
ok, heres a summary : downpipe tacked, wastegate remains to be merged in, exhaust cut out, fitted up and tacked from end to end, deck screwed on for good, neat little bracket made to pretension the rear muffler mounts like nissan has done on my skyline. (no harm in swiping others good ideas) and i only started at 2pm. its 2:30 am now, and i finished on it at 2am. 12 hours on the ute, and the morning spent properly cleaning up the carport...
things are looking good for some combustion later this week!
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