Puma Cosworth restoration/bodge job fix!

[warrenpenalver]

While im sorting out various bits and bobs ive decided to start my digital dash wiring plans. Ive had to put my "3 button remote" conversion on hold as im struggling to find a second hand mk4 fiesta/early puma alarm module as my local scrappys only seem to have base spec fiestas with no alarm system!!!! anyhow.... i have aquired a digital dash from a late puma: And the connector with it: I also want to try and fit this: An ST170 focus dash!! Same level of technology and uses same kind of data inputs as the puma digital dash so i should be able to make it function. Primarily want it for the 160mph clocks and the fact its different!! Also going to rewire the dash illumination to utilise the dash dimmer switch from the focus. Looking at the focus plug: its simple computer pins and socket technology in the connectors so easy to connect up once ive done the wiring diagrams i need. Ive got some pin strips for the loom: and some connectors for the plugs:

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[Glenn.]

Wow ive just read all the way throught this thread.Top work and loving the puma.

[warrenpenalver]

Well i been working out some of the wiring for my dash.

This is the 2 connectors on my current loom:


I have worked out all the pin functions and stuff i need to transfer accross and labelled each function.

Ive then done the same on the puma digital dash plug:

Labelling all the functions then transferring across functions i already have on analog loom so i know which pin to connect to which and where new wires need to be made into my loom.

Ive done the same on the focus plug:


Next step is to turn them into loom plans and get some spare connectors to hack up!!!

[warrenpenalver]

Well ive finally finished the wiring diagram to run a puma digital dash in an analogue car!! So just the loom to make, then send it to a guinea pig with an early car to test it (my car doesnt have speed sensor as standard and i dont want to fit a part if there's fundamental flaws with my plans, where as a normal car theres no permenant changes).

first of all i need to make a plug to go into analogue loom plugs. These are not available as they are an integrated part of the dash clocks so ive made my own using 2 sided copper clad board.

First i cut rough shapes then filed them down to fit:


Then tweaked them to fit the connectors:


The next stage is to separate the individual pins which i can do with a cutting wheel on my dremel (the quick easy way ) or by buying etch resist pen and acid etching the board, proper PCB style like i was taught years ago!!! Not made my mind up yet!!! I might just use cutting wheel for the prototype and if its something people want me to make for thier cars then i might then do it properly!!!

This is the wiring diagram!


Also been checking a few bits and bobs ready for MoT and getting the car back on the road.

[focus 4x4]

Quality!!!

[Moonstone Mart]

thats some quality wiring design and knowledge Warren!!


Good work.


Mart.

[warrenpenalver]

Attacked the connectors with the dremel tonight!!!

Cut them a bit shorter and seperated each track on both sides:


Fits fine into the connector leaving me space to solder the wires on:


as you can see i have good contact on the tracks from the connector:



Also found an interesting part today. Im looking to fit a part from a range rover sport to my car for ultimate bling factor

this is it:


Notice the similarity between the ford equivilent:



Been doing more work on the focus dash conversion plans too. Its getting a bit more complicated now as i need to fit the trip computer module and also need to work my head around the Standard Coorporate Protocol BUS that comminicates between the dash and the ECU so i can get speed, tacho and engine temp feeds!!!

This is the sort of stuff ive been getting my head round:

Ford SCP message construction
Message byte # Description
1 Upper nibble is message priority, low number is high priority.
Lower nibble is message type (see next table).
2 Destination address, physical or functional.
3 Source address, physical address of the node that transmitted the message.
4 - 11 Message data, if present.
12 (or last byte) CRC byte.

Ford SCP Message Types
Message Type Description
0 Function message.
1 Broadcast, a type of functional message.
2 Function query.
3 Function read.
4 Node - to - Node. A physical message.
5 BCC access.

[Glenn.]

Wow your a clever man.I hate wiring.

[warrenpenalver]

Been doing a bit more wiring diagrams tonight.

Finished the focus wiring loom to fit ST170 dials to an analogue dash puma. These are better as they come with a separate oil pressure/temp guages which will save me fitting expensive ones!!


ive had to go onto 2 pages with these diagrams due to the complexity:



Still a few bits to be worked out before i can begin to make the loom. First of all i need more info on the workings of ford's EECV and the SCP databus!!! on the focus and other EECV cars, the ECU feeds the digital dash with various info via the SCP databus. On the Puma, the databus is not connected to the dash (even on the digi dash cars) so i have concerns on if the SCP databus is able of communicating with the dash or not. The databus on the puma only feeds the Data Link Connector for diagnostics purposes, so i need to find out if the ECU requires another wire feed to "trigger" the databus.

The joy of a databus is once ive got the databus live, then it doesnt matter that its only the dash sending info requests as the ECU will just respond with the required information or an error code if theres a problem.

But i wont really know this until i get to play with it properly once a prototype loom has been made.

[dingla rs]

omg hw the hell u work that lot out ,u sum kinda wire wise lol

[focusjohn]

If that works your officaly a genius as well as a nutter lol.

[warrenpenalver]

most of its quite simple really, you just have to be very systematic, work out what each function is on your current dash, what each function is on new dash and match accordingly.

the difficult bit is that some outputs are supplied differently so you need to work around that. eg speedo being on a cable or speed sensor on early/late puma but being based around a speed sensor output down a databus on the focus!

[parcs]

From the amazing quality of work shown in this thread; I think you may already know that a nibble is 4 bits and a byte is 8 bits. I have been in the computer analysis business for 42 years and it has probably been 30 years since I have heard anyone refer to a nibble. So I thought I should say something just in case.

[warrenpenalver]

lol parcs. Im hoping i dont have to get anywhere near actually doing any programming. Im hoping to be able to use the SCP databus without software changes. But we shall see.

Well i bought myself some wire today!!!!

[focusjohn]

Pardon me for sounding thick its all the same colour?

[warrenpenalver]

yeah it is Im not buying like 22 reels of wire to get the colours i want.

[focusjohn]

Originally Posted by warrenpenalver

yeah it is Im not buying like 22 reels of wire to get the colours i want.

Have fun then iuve tried that before and its confusing. Id sugest buying trailer board cable cheap and has 12 different colour inside it.

[warrenpenalver]

I just do 1 wire at a time so theres no confusion.

[warrenpenalver]

done a bit of soldering tonight!!


double insulated everything, first with heatshrink:


then with tape to finally seal it in and hold the shape.

[warrenpenalver]

fitted the new tyres ive had for a while:

[warrenpenalver]

well ive finished the prototype loom for the puma dash:


its not as tidy as i want it to be but is fine for a prototype. Id do a couple of things different when i make another and probably put nice braid and stuff over it to make it look nice but otherwise its basically same.

[Mister G]

Awesome project, hats off for attempting the wiring! I had an escort once where somebody had actually twiddled together the wires and taped them to the bottom of the fuel tank with gaffa tape. I was shocked when I saw it!

[Moonstone Mart]

Nice work Warren.

[lanfire]

them clocks are going to be very cool when there all working is there much of a size difference to the clocks? or does it just fit straight in the puma dash?

[warrenpenalver]

The focus clocks are very similar sized but slightly wider at the corners but i should be able to fit them anyway or trim a little bit of plastic.

today i decided to pull out my idle control valve for a bit of a clean!!

[Jackstrath]

i love the look of these! ,and the fact yours has a cossy in it is ace! , must go like stink! , some scary bodges there tho!

[warrenpenalver]

Ive finished another wiring diagram!

This one is for me to be able to fit a 3 button remote alarm module to an early 2 button IR remote alarm car.

[CarbonRick]

Lookin good mate. Keep it up!

[warrenpenalver]

Well been doing a little bit of minor fiddling and MoT checks.

Been looking at my ISCV and i still cant work out how this hole gets sealed by the ISCV plunger??


Also been playing around with my rear struts. Thought id have a look at the rear mounts to see whats what for when i get round to replacing them.



As far as i know thats a mk2 escort rear top mount assembly!!

[lanfire]

JESUS ok that rear strut is not good !!

[warrenpenalver]

why is it not good?? its structurally soundand is braced in the corner with reinforcements.

The only concern i have is its a potential place for rust to form being unprotected from spray plus the fact ive got different dampers front and rear which is pain in the arse for replacing things!!

I'll probably get cossie rear turrets fitted over winter so i can fit the longer escos rear coilovers so it all matches up and cheaper to replace in future. Will probably need the rear of the inner arch extending a bit so that i can avoid contact between coilover and inner arch. (which is probably why it was done this way in first place.)

[Lee_R21Turbo]

I think he means the big chunk of metal missing in the top spring carrier - unless its supposed to be like that??

Fair play for all the wiring mods - very impressive stuff!!!

[warrenpenalver]

that metal is meant to be missing. I think its so you can remove it when disassembled. Even the pics of similar gaz coilovers show the same.
see:

[e30cossie]

Keep up the good work warren. I have always liked this car and in my opinion it is in the top 10 cars on passion ford.

[warrenpenalver]

thanks LOL although at the moment it also has the top ten bodges on passionford too

[focus 4x4]

Cant wait to see the clocks all finished and working!!

P.S watch out for the leaks in those Gaz shocks!

[warrenpenalver]

those arent my gaz shocks in the pic just a google robbed pic!!!

My car has AVO's at present. i thought AVO's are worse than Gaz or are they all just as bad as each other??

[lanfire]

Originally Posted by Lee_R21Turbo

I think he means the big chunk of metal missing in the top spring carrier - unless its supposed to be like that??

Fair play for all the wiring mods - very impressive stuff!!!

yes i was meaning that hehe, iv not seen top cups like that, you learn something new everyday

[J98 FYA]

any update on this warren u electrical whizz

[DanCossie]

Warren.....Do you want to sell me this as it is ??? Genuine Question Mate