November 19th 2011 - Reversing and Fog lights

Having added the remaining connectors at home, we returned to fit them.  We'd worked out that the grommets supplied with the kit would be too big to fit between some of the mounting lugs, so bought some 25mm versions from B&Q, which turned out to be ideal.

Having seen the "A Racing Car is Born" DVD, where the guy doesn't fit his SVA/IVA stuff until after the build and regrets it, we dug out the brackets to make the reversing at fog lights sit vertical (a legal requirement).  We had to enlarge the central hole in these as they were not designed for the connector to pass through (and were starting to wonder whether we'd made the right decision on pre-fitting the connectors).



Rear of reversing light showing IVA bracket, grommet and new connector

That done, we masked up the area where the lights were to go and measured up (several times) to make sure the lights would be level with the main rear light units and symmetrical with each other.  We then chain drilled and filed the 25mm grommet holes and the smaller ones for the mounting lugs.

Masked (hurriedly), marked, drilled and filed ready to accept the reversing light

Then followed 4 or 5 trial fittings to cut the right size slot in the to of the IVA bracket to prevent it fouling the grommet.  It seems like a lot of effort to avoid the pain of fitting the connectors in situ, but should make it a lot easier should they need to be replaced.

Reversing light viewed from above. Cut out to provide clearance for grommet clearly visible



The finished job is pleasing, but belies the amount of effort put in!



October 2011 - Lighting connectors

To make some "easy" progress, we connected up the headlights.  This involved fixing a connector block to the metal spade-like connectors on the end of each wire - easy enough.  Spurred on by this, we decided to do the same for the rear lights, but this was more difficult because it involved removing an existing connector, adding the spade-like connectors (which need crimping) then pulling them into a connector block.  This was not easily carried out within the wheelarch and with an old set of pliers, so a different approach was needed. 

This approach was to take the light units (including the fog light, reversing light and front indicators) home and fit the connectors there.  This has the advantage of being sure of a good connection (things are usually easier sitting on a sofa than when hunched under a car), but has the disadvantage of needing larger hols in the bodywork to fit the connector through.  We did manage to get one light unit wired up OK though:

Rear near side wheelarch showing cable coming from rear lights

September 2011 - Gearbox filler

I'm sure we did slightly more in September, but it must have been fairly unproductive, as the only photo I have is of the hole we made in the passenger footwell to allow easier access to the gearbox filler plug/hole.  We'll make a hinged cover for it later.  Unfortunately I didn't have an allen key big enough, so had to buy a "proper" set.  However, the plug still wouldn't undo - reading up on this afterward I found that they are typically VERY tight - I'll have to use a longer bar to turn it.

August 2011 - Routing the ECU cables

Limited amount of time to work on the car, or even update this blog, so we'll do four months' worth at once.

In August we tackled a job we'd been putting off for ages - routing the ECU engine wiring through to the engine bay.  It was of those "if only we'd plannned ahead and put more clips inside the tunnnel" moments and without them, the options were:

1. Take the wiring through the bulkhead (untidy)
2. Undo the cable ties in the tunnel for the main loom (hard to get at without risking damagine the loom)
3. Try to get some more clips in down the other side of the tunnel (hard to get the drill/riveter in)

We went for option 3, and it turned out slightly easier than it looked, and the end result was tidy:

After this, connecting the engine wiring was relatively "plug & play", although there's still one "spare" connector and the hole for the exhaust gas sensor to make.  Not sure if I'll do as others have done and get a replacement connector so it doesn't need a massive hole in the side of the body.