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Steve’s FW 2.0 Zetec build – January 2021


SteveB21
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4 hours ago, Ian Kinder (Bagpuss) - Joint Peak District AO said:

Also at IVA how can you demonstrate it's suitably clipped and protected if it can't be viewed?

If he can't see it, he can't say it isn't! I take your point though Ian.

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Spent a couple of happy hours fitting the pedals while I wait on a delivery of convoluted sleeving for the wiring harness. All very straightforward.

 

Following @Ian Kinder (Bagpuss) - Joint Peak District AO's suggestion I've replaced the throttle cable with Teflon coated bike cable and it runs very smoothly, with the added bonus that the slightly thinner cable meant I didn't have to drill out the brass pedal trunnion! I'll keep the original inner cable as a spare, just in case...IMG_4940.thumb.JPG.a95ac297c5043b2b51ec836c09cbab3f.JPG

 

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Dug out the OMEX ECU loom and labelled up the engine harness to make sure everything goes in the right place, but I cannot find a 44mm wiring grommet for the scuttle panel to use where the ECU loom goes through - any suggestions on where WSC might have hidden it? @MikeJG @Benrobson2999?  Looking ahead, I assume the washer tubing goes through the same hole as the ECU loom?  Thanks!

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9 minutes ago, SteveB21 said:

Dug out the OMEX ECU loom and labelled up the engine harness to make sure everything goes in the right place, but I cannot find a 44mm wiring grommet for the scuttle panel to use where the ECU loom goes through - any suggestions on where WSC might have hidden it? @MikeJG @Benrobson2999?  Looking ahead, I assume the washer tubing goes through the same hole as the ECU loom?  Thanks!

 

Strangely @SteveB21they don't seem to supply one but I asked nicely and WSC sent me a couple extra. I reckon the grommet kit was set when they were still supplying carburettors. I decided to run the washer tube separately and drilled a small extra hole and put in an appropriate grommet I had in the cupboard. Both methods fine I'm sure.

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Thanks @MikeJG I shall ask WSC nicely for one tomorrow. I like the idea of a separate hole for the washer tubing and like you I’m sure I have a suitable grommet hidden away somewhere. 

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Westfield are sending me a wiring grommet for the ECU loom and I've been ticking off various jobs.

Fitted the washer bottle and swapped over the electrical connections (the loom came fitted with an Econoseal connector).

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Used M6 dome head screws and will fit nut covers on the inside:

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Fitted the fuse boxes through the scuttle panel and fitted rivnuts to the panel so I don't need to worry about accessing nuts under the panel if I need to remove the fuse boxes in future.

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Went a bit OTT on labelling the fuse box connections...

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Also fitted DynaMat under the panel:

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Fitted countersunk M5 rivnuts to the chassis for future use in securing the coolant pipe P-clips along the front of the scuttle panel:

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Had a bit of a frustrating afternoon - went to fit the engine harness and bent one of the pins in the 4-way connector on the main harness that connects to the engine harness😬. Top left in this photo.  I've sent an email to Ian at WSC, but does anyone on here know the trick to extracting the pins out of this connector?  They don't align very well, so will have to take more care once I have a new pin in place.

 

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Did have some small progress elsewhere though - sticking sound-deadening mat on the passenger footwell side panel, with aluminium tape on the front edge.IMG_4971.thumb.JPG.b9a4277eb5e1a0a4d50ecc4f3c39dbf1.JPG

 

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Thanks Rich - that makes sense. I'm used to using a small screwdriver on other connectors, but that wasn't going to work here. Hopefully I've not squashed the pin so much that I can't get access...  

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Did a bit of research and found out that the 4-way connector is a Delphi "Weather Pack" connector (20A rating). WSC are getting some new pins from the harness manufacturer for me - apparently bent pins are not a common issue for them! The pin is held in place by 2 tangs, so I got a cheap set of pin extractor tools off Amazon overnight and they failed to do the job - there was a tube tool of the right size, but it was made of such thin metal that the damaged pin distorted it, so proper tool now on order (A Delphi 12014 extraction tool for future reference).

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If all else fails, the connector bodies are actually quite cheap and I can just cut apart the existing connector and fit a new one.  Leaving the main harness and engine harness loose fitted just in case....

 

Got on with a couple of other jobs - fitted a splash proof fuse holder at the front of the chassis for the battery charger wiring, used rivnuts and M5 screws:

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Trimmed the passenger side tunnel panel, fitted Dynamat Superlite on the inside and fitted both the tunnel panel and side footwell panel.  Feels like a bit of a milestone with first major panel in place. 

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Fitted Aluminium tape over unused front seatbelt mounting:

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Dynamat fitted:

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Panels in place:

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Steering rack today - all very straightforward.

 

Got the grinder out, took 10mm off each end and fitted the extenders as per the manual:

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Fitted the rack using 30mm M8 bolts rather than the 25mm that were in the steering pack to ensure plenty of thread once torqued up.

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Finally, these were in the bag of steering rack bits - I'm sure they are a vital piece of IVA kit, but where do they go??

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5 minutes ago, SteveB21 said:

 

 

Finally, these were in the bag of steering rack bits - I'm sure they are a vital piece of IVA kit, but where do they go??

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Left mine off. I am probably wrong but something to do with the front shock collars.

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53 minutes ago, Si.Dalziel said:


Left mine off. I am probably wrong but something to do with the front shock collars.

They are supposed to cover the Shock adjusting nut but not required .

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