October 30, 2020.

Carrying on from the last post more wiring was needed for the engine, the wiring on the engine I’ve broken down into a series of sub-harnesses so if there’s an issue or something needs to be changed I don’t have to have a go at the entire system but just deal with a smaller part, the basic breakdown is, injection, ignition, instrumentation and the idle air control valve.

This is the rope model for the ignition…

This is the ignition in progress…

This is the instrumentation completed, coolant temp, throttle position and inlet temp for one side of the engine and crank and cam sensors for the other.

These are the plates that the wiring straps to.

Next was to fit it all to the engine, I expect this will need repeated fitting but here is the initial go at it.

Next was the bracket to hold the connectors in place. 3D models of the the Deustch DT and DTM connectors I’m using can be downloaded from TE Connectivity Using these I could design the arrangement to hold them all. I also printed off a holding clip direct from the 3D model of it, which worked very well, from there I design some ganged clips to hold all the required receptacles.

The design for the holding plate then came out like this…

The plate in 1.5mm aluminium was cut out on the MPCNC…

Then folded to produce this…

This will be glued in place with sikaflex, approximately like this…

In other work done the hard lines for the fuel tank are now complete and tightened down, the last do do was the vent line, which currently finished behind the drivers seat, this needs to be completed with a charcoal canister and other parts required for emissions compliance, but now I have all the parts in place to enable fuel to be run to the engine, next up for that will be a leak test.

The fuel tank cover and other pieces need to be trimmed before screwing into place the which means this needs to be done before the fuel tank filler hose can be put into place. I’ve started on that with the simple pieces to begin with, this is part of the fire wall. with the unbranded Nomex type material on the passenger side and the DEI heat screen material on the engine side.

These panels bolt with lots of 4mm bolts to flanges welded to the roll frame. Other parts of the firewall in progress…

On nearly all of these panels the edges of the material is trapped in place when attached so if the adhesive fails the material will be held in place. The adhesive used is a contact type meant for headliners, I’d have preferred to use something fire resistant but could not find anything suitable.