Another 90 Rebuild

Al2O3 · Dec 24, 2015

The first picture is for TorsionBhudda

Cheers, mate.

I then set about moving the instrument binnacle. Got to this stage and then had to remove the steering column bracing bar.

Once that was out of the way the harness could be dropped in place over the column and all of the connector blocks put back together.
Then put some new white fixing blocks in to the holes in the bulkhead.

I put some sealant foam around the heater hole in the bulkhead and some around the hole in the dash panel to match. Hopefully, that will prevent any valuable heat leaking out

Getting the lower panel in to place still isn't easy. The wiring harness is heavy and stiff, probably with the cold. Putting the steering column surround on is looking like a mistake, so that is probably going to have to come off again.

Got the call for a bacon sandwich at this point, and the light was fading anyway, and so that's as far as it's getting until after boxing day.

TorsionBhudda · Dec 24, 2015

Al2O3 said:
The first picture is for TorsionBhudda

Cheers, mate.

I then set about moving the instrument binnacle. Got to this stage and then had to remove the steering column bracing bar.

Once that was out of the way the harness could be dropped in place over the column and all of the connector blocks put back together.
Then put some new white fixing blocks in to the holes in the bulkhead.

I put some sealant foam around the heater hole in the bulkhead and some around the hole in the dash panel to match. Hopefully, that will prevent any valuable heat leaking out

Getting the lower panel in to place still isn't easy. The wiring harness is heavy and stiff, probably with the cold. Putting the steering column surround on is looking like a mistake, so that is probably going to have to come off again.

Got the call for a bacon sandwich at this point, and the light was fading anyway, and so that's as far as it's getting until after boxing day.

Glad I could help lol Have a Merry Christmas mate

Brown · Dec 24, 2015

Starting to look like the interior of a car again. I know what it's like to have to go back and take things apart again - I've had to do it a few times with my gearbox adventures recently. But each time you get a little further forwards, so it gets done eventually!

mark-d · Dec 26, 2015

It's coming along nicely

I will have a go at putting my dash back together tomorrow, do you think it's better to start with that large bottom piece? It's about a year since I took it apart and I lost all my pictures

Al2O3 · Dec 26, 2015

Yes, I see no reason why not to start with the bottom section. If you've taken the plastic steering column cover off, that needs to go on first. Good luck and if you need any pictures I may be able to help.

Al2O3 · Dec 31, 2015

Over the last few days I've just been tinkering on with the dash and it's in as far as it needs to be at the minute. I've lost a grub screw out of one of the heater cable clamps, so I'll have to try to track one down.

Next step, I'm thinking, is sorting out the earth and live cables and then getting the seat box in.
Took the gearbox earth off and cleaned it up.

About ten inches along this earth cable there is another earth tab, but I can't find where it goes on my pictures.
This is it.

It either goes on to the chassis or the seat box I'm guessing. Can someone please tell me

The shiny earth connection above is now covered in copper slip in this picture.

aaronmorris · Dec 31, 2015

Yep that little tab doo-dah goes to the chassis, mine was bolted through with one of the gearbox crossmemeber bolts.
Good to see progress has continued over the festive period

Al2O3 · Dec 31, 2015

Thanks for confirming that Aaron. It reaches nicely to the cross member bolts, but I wasn't sure. I've been oiling the difflock linkages, though they were moving quite well. I'll give them a further clean before greasing them up and then it's time to put the seat box and the floor in I reckon

Karls · Dec 31, 2015

How did you manage to route all the wiring correctly? Was it from previous dis-assembly pics?

Al2O3 · Jan 1, 2016

Yeah, dis-assembly pics, but I labelled every connector and spade end. Without the labels I would have struggled.

Karls · Jan 1, 2016

Oh bugger!
Mind you, the wiring I took out was truly like something out of an Italian recipe book. So many different coloured wires, even on one run; dry joints just twisted together so I thought it was pointless labelling as I decided it was new looms time.
Now I'm almost at the point of installing these new looms...

Al2O3 · Jan 1, 2016

Good luck with it. It's the terminals to the dash instruments that will be tricky.

Al2O3 · Jan 23, 2016

Well, slowly, slowly catch a monkey I reckon. Got a few little jobs done today.
I've attached the chassis earth cable to the gearbox cross member bolt. It's a new cross member and so it was painted with rustoleum. No good to get an electrical connection to!
I'm hoping that it will get a good enough connection through the bolt to the other side of the chassis rail? What do you think?
I lightly rubbed down the chassis rail around the bolt hole and it's a brand new shiny bolt.

The brass tab was cleaned to a nice shine too, but it doesn't look it in this pic.

Will this be sufficient?
Refilled the transfer box while access was easier. I usually use an old pump garden sprayer with the nozzle removed off the hose. Improvised with a milk carton funnel.

Discokids · Jan 23, 2016

For the earth, you could always just make a short length with a crimped fitting each end and loop it from one side of the chassis to the other, or from the battery or block to a different location on the chassis. Looking great by the way, I'm dreading putting the dash back together, it's one of the first bits i removed, rather enthusiastically, and I have no idea how it all goes back. I'm looking forward to the wiring though.

Al2O3 · Jan 24, 2016

Discokids said:
For the earth, you could always just make a short length with a crimped fitting each end and loop it from one side of the chassis to the other, or from the battery or block to a different location on the chassis. Looking great by the way, I'm dreading putting the dash back together, it's one of the first bits i removed, rather enthusiastically, and I have no idea how it all goes back. I'm looking forward to the wiring though.

Cheers, Discokids, That had crossed my mind about another strap. It's a good idea. I think I'll look up some of the tabs and some thick cable and put something together.
I've qot quite a few pictures of the dash coming apart, if you need them when doing yours.
Are you serious about looking forward to the wiring?

If I hadn't labelled all of the terminals for behind the clocks I would have been stuck. I'm not too keen on the electrickery bits.

Discokids · Jan 24, 2016

Cheers Al, that would be much appreciated, but it's a few weeks off yet. As for the wiring, yes. My loom is a mess, nothing is labelled, and what I have doesn't correspond with any diagrams I've found. But I'm really excited about sorting it out.

Al2O3 · Jan 24, 2016

Discokids said:
Cheers Al, that would be much appreciated, but it's a few weeks off yet. As for the wiring, yes. My loom is a mess, nothing is labelled, and what I have doesn't correspond with any diagrams I've found. But I'm really excited about sorting it out.

Well you must be fond of a treat.

However, that level of enthusiasm for a task like that must mean that there is a fair bit of know-how behind it. I think you'll be alright!

Al2O3 · Jan 24, 2016

Another mild afternoon and got the difflock linkages greased up. Had put some oil on the joints a few weeks ago and left to penetrate. Covered in grease today. The difflock lever changes very smoothly now

Got the fuel tank in.

The front cantilever bracket wasn't perpendicular to the chassis rail and so I had to pack the bottom bolt of the three with a couple of washers.
Managed to get the tank to lie parallel to the middle bulkhead body, after a bit of fiddling.

Started sorting out bits of wiring harness that were held up out of the way behind the gear lever.
The writing on the masking tape labels I put on the connectors has faded

I've been using a magnifying glass to try to work out what they say, but the only one I could eventually read was a round push connector that said 'hand brake'.
Does anyone know what the connectors might go to

The two spade connectors that have tape across them on the left were just loose and hanging there not connected to anything.There are two spade connectors on the right with tape across them. I can make out 'SSE G' so i think one word is PASSENGER and the other word looks like LEVER There is a third word that looks like it has an F in the middle.

Mystery%20Spade%20Connectors_zpsy53pnyba.jpg

I'll try to find a wiring diagram, but if anyone knows where they go I'd appreciate the info

Karls · Jan 24, 2016

I'm about to start assembling my dash so would very much appreciate the pics you mentioned earlier of your dash dis-assembly if you don't mind please?

Al2O3 · Jan 24, 2016

No bother, Karls. I'll create a public folder, in my Photobucket account, and upload them. Once I've done that I'll post a link on this thread that will take you there.

Another 90 Rebuild

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