wow! very nice!

 

Updates Will?

 

Since you asked nicely

I've been nibbling away at loads of little jobs as and when i've had time but the major one has been making a mock up of the wiring loom ready to fully rewire the car.

Anyhoo - i'll let the pictures do the talking

New washer bottle & pump


New hydraulic handbrake, switch panel box, lifeline control box etc.


Aeromotive fuel system mocked out in spare wheel well:


Pedal box and hydraulic switch:


Fuse, battery isolator, battery box mock up etc:


Mock up of rear end looms etc:


New modular fusebox and power distribution box crudely rape taped in place for mockup


Engine back on a stand for new engine loom mockup:














Can you say 'Drive By Wire'?




Battery box final fitted - rivnuts fitted to boot floor:


Modular fusebox final fitted - rivnutted to bulkhead:


Power box mounted on anti vibration mounts (more because the back of the box had exposed live contacts and I wanted them insulated and well clear of the bulkhead!)


Got a good mate up for the day tomorrow so hopefully we'll actually start final fitting the chassis loom! More updates as and when I can

 

Very nice! loving the engine, so is the white wire just for the mock up and get a rough idea where the loom is going then?

 

I think you should wire it all in imperial blue, just to make life more interesting

 

Just out of interest, the pedal box you are using is that an OBP one? If so is it the universal jobbie or did they make one for the Focus?

 

looking good will!

 

god your wiring guy must be good with every wire beening same colour

 

You'll find there probably all numbered or lettered Andy

 

White wire is actually MIL-SPEC lightweight thinwall so will be staying!!! Dave popped up a few weeks ago and we did a full mock up, from that I calculated the acceptable minimum thickness wire I could use and made a full wiring diagram up with identification, source, destination, what fitting is at either end, wire thickness etc. All good fun to say i've got nearly 20 pages of an Excel spreadsheet full lol. I'm actually doing this for my university Major Project so i've got to document it all - up to around 100 pages so far!

Yes. Thanks for that New family addition all good I hope mate?

It's an OBP one mate, FF007 I think was the part number!

Cheers dude!

In answer to both your questions...



I have Dave to thank for getting all of these printed for me! Dave's background is military aviation whereas mine is purely autosport. I spent a fair amount of my apprenticeship in F1 designing and making wiring looms so fortunately neither of us was particularly daunted by scenes such as:

This...


Turning into this:


Anyhoo, in no particular order as it's getting late and after a long day and evening of wiring i've no intention of sorting!







Can you guess what this is for?


Ta-Dar!


No more fumbling trying to get a jump pack croc clip onto a race battery...


Isolator system etc.




Starting to shape the loom into something more managable:






Switches mounted - in order of severity left to right lol:


Fuel System wired:


Made a start in the engine bay:





Dave is staying over for one more night so will hopefully get a mornings worth more in tomorrow before he has to set off home!

 

Wow never seen this one. loads of ace race car touches inside, love it

 

looks mint will when do you want to start my loom

 

Hi mate, quick question,
what is that thermostat housing off off? Old mk5/6 escort?

cheers!

 

Looking good Will I Am

 

Looking forward to today's update. Can't feel the ends of my bloody fingers for all the lacing that's been done today!

Been bloody good to see you again mate, sorry we didn't get quite as much time as originally intended but I still think we made decent progress despite that which the photos should show.

Just to further expand on Will's comments though, I joined the RAF nearly 9 years ago as an aircraft electrician (power generation, regulation and distribution), later adding avionics (navigation, communications and radar), databus and fibre optic to my repertoire of skills - so if it works but you can't actually see it working then I can (in theory) fix it. I've done more than my fair share of loom building though so this has been good fun and a decent learning experience working from effectively with a blank canvas, especially as i'll be doing my own engine loom for my own build later this year.

Come on then Will, let's 'ave the rest of it.

 

Cheers for all your help Dave - we definitely broke the back of it these last few days!

We didn't actually get that many photos that'll be of interest to the wider world

Few quick pics of todays progress and Daves' speed lacing

We actually spent a fair amount of time working out the best routing of things and working out where to secure/mount:

This was just an example on the tailgate:


Heatshrunk sections where passing an edge to avoid chafing:


And then onto sections with a few more wires in:


Before we knew it, a rough shape was appearing!






And the sea of wires we saw yesterday is now tamed to this:


You can tell Dave does this a lot more often than me , sadly he had to set off home just after lunch but left me at a point where I can tidy up/tweak/terminate etc.

After he left I got a bit more done, just tidying up etc:

For example, this:


Turned into this:


Overall, we've made brilliant progress! Many, many thanks Dave - good to see you again mate and I definitely owe you a favour!

 

Looking good! Can you tell me how the printing is done, and is it the cable ends, or applied right along the cable so its still present if you cut it back?

 

excellent progress Will wiring is one job that i do not like doing

 

Wow I havnt come across this project before but wow just read it from the beginning, I am going to do a zetec conversion on my sapphire and was thinking of going twin charged but didn't even know if it could be done on these engines, would you say the extra expense and time of having to fit both forced induction setups together is worth the gains?

Regards Matt

 

brilliant progress! one question though, do you wrap the wires in anything when you have finished or will it all remain on show in the white colour?

 

Dave got the wire laser printed for me with an ident every 150mm!

Cheers Andy

 

Matt - it's looking like I might be moving away from the twin charged setup now. Basically, money is tight while i'm at uni and I can't really afford to do it to then find it's not 100%. The big problem for my setup was the air charge temperatures. All of the boost goes through a small chargecooler core inside the Powerworks supercharger plenum. I genuinely think that the extra air from the turbo would be too much for any sustained (20 minute track sessions etc.) abuse.

So, it's looking like a good friend of mine is going to buy the supercharger and i'm going to replace it with a Jenvey inlet plenum and potentially a dry sump kit!

If you can afford to do a twin charge setup 'properly' in the form of ECU controlled bypass valves etc, then the gains can be awesome if you're going for big numbers! But on sub 600bhp stuff i'd say just use a decent turbo like the GTX series from Garrett.

I'll leave them as they are - no reason to hide it

 

Looks great will.

Agree with leaving the wires open too. They dont really need alot of protection inside the car, and if a repair is required it will be a relatively fuss free procedure.

 

were do you buy such wire from and what sort of mm/gauge wire do you use i need to make bits and pieces for an engine loom. this project is looking excellent

 

I use various places for my stuff but tend to favour www.polevolt.co.uk for a fair amount of it!

It all depends what sort of current you'll be seeing in your circuits as to what gauge wire to use. I've changed a lot of my lighting circuits to LEDs to get away with much thinner gauge wire.

Engine loom wire, minimum i'd suggest using would be 20AWG really.

 

Thanks a lot much apreciated

 

Some thought going into this will! Did you get my pm on the airbag module?

 

Yes mate, just replied! Sorry it's taken a few days

 

Will what sort of cost do you recon it would cost to do a in car loom for lets say....... My car LED's sound like a good idea too

 

Depends how you want to do it mate, i.e to go for a completely new fusebox setup etc.

All the parts for mine, wire, fusebox, heatshrink, terminals, switches etc. etc. have probably come to around Ł400-500.

Labour wise is the killer though! We can work something out on yours though mate. Have you got it back yet?

 

Top work Will.I bloody hate wiring and that looks a right nightmare.

 

Nice spec Will, Jealous as usual.

 

comedien now are we will lol

 

That's a no then...

 

Looks great

 

Fpmsl Gits....




No car just yet lol


But basically Will, half dash new fuse box in center, unsure yet as to bin the abs or have it on a switch?. Was thinking about running LED's on mine too, ever since Smit posted about the rear numberplate bulbs

I was also thinking about getting a basic kit car loom from PWS mate...

 

Looking good


Brian

 

Quick update!

I've been flat out lately trying to get all my uni work sorted so not got as much done as i'd wanted, but here's some progress shots.

I'm going turbo only now for Time Attack and am going to be running a Jenvey inlet plenum, however, when I rang up to order - the lead time wasn't going to get one here any time soon!

So, a quick phone call to Neil from Fast Ford and the offer of a hot meal saw me driving down to pick up his inlet to make my wiring loom up on!

So, mocked up on my engine with my Drive By Wire throttle body on:


New Bosch 3.5bar TMAP sensor arrived:


Made a start on the engine loom by terminating the engine half of the bulkhead connector:


Which was then laced:


Sleeved and shrunk:


Glued:


And booted:


Then it was on to lacing the divisions:


Before sleeving them:


Waiting on the postman tomorrow with a load more goodies so will hopefully be able to finish the loom off by the end of the week!

 

That looks fantastic bud

 

Really nice work mate Will.