Fair play to you for even attempting that, I'm still plucking up the courage to make a start on making and fitting an uprated headlight loom on both my RRC and 200Tdi 90, a la M H Man.

Thanks, it's the bit I've been looking forward to the most. It's been at the back of my mind throughout and if I ever thought of anything I would write it down, so I didn't forget. The Haynes manual has been a bit of a help but there are so many mistakes. I laid out my old loom on the table, stripped it and mapped it out colour by colour, to scale, on paper. Looking at the manual every day for a month and I still can't fully decide what year my wiring equates to. Anyway, about my own loom - here it is:
The right hand stuff is complete, just need to shrink the shrink wrap and put all the terminals on.
Left side needs a trim, the two massive coils contain enough cable to go all the way to the front lights, don't want to cut it until it's in position. The side cutters are there to show where it exits through the bulkhead into the engine bay.
Starting where the cutters are going clockwise;
L/h front lights
Rogue wire is glow relay
Engine bay fuse box
Engine sensors
R/h front lights
Rear end
Front wipers
Heater
L/h heated mirror and door switch
Dash centre console
Stalk switches
Clock and r/h heated mirror/door sw
Warning lights and gauges
Hazard Switch
Ignition switch
Brake pedal switch
Heater controls
Relays
Fuses

Total cost so far is around £100 on cable and a few minor crimps but I did already have some cable which I estimate reduced the cost by about £30. Then there's the chassis loom which I think cost about £20 in wire, then the superseal connectors of which I've ordered about £60 worth so far. Still need headlight connectors and a fuse / relay box which is coming to around £80. Also need an ignition light resistor and I've only put a few earths in so far but will carry on with that soon enough.
There are a few more bits of wire to put in but these are between the engine bay fuse box, the interior fuse box and the relays. I need to get this mounted before I can proceed.
If it all works, I'll publish my diagram (that I've been writing as I go) but if it all goes up in flames I'll probably not bother.

So, it fits.
Gauges and stalk wiring is perfect:


Fuses and relays area is plentiful:


Centre console offshoot, this did need tweaking to get it closer the centre so it's been untaped and moved over by approx 6cm, I couldn't get any more without redoing a joint so hopefully this is ok.


Wiper and heater wires about 8" too long:


Plenty out here for the front lights, engine loom and fuses;

Passing through the bulkhead was a doddle, I wasn't sure about getting all this cable through a 42mm hole but there's loads of room to spare. I've got all my econoseal connectors on which has taken all afternoon, too dark for photos though. Need to find somewhere in the engine bay for a fuse box now. Passing through the bulkhead left such a gap I wanted to seal it but still be able to pass cables through if need be (still got heated screen cable to get in) and thought some convoluted tube would be perfect but couldn't find it locally in 40mm. Then I found some very locally -



And while mrs discokids was at work I thought 'in for a penny, in for a pound' and used a knife from the kitchen to carry out my crime.
I'm pretty sure she won't notice 6 inches


Bit of tyre soap and pushing and shoving and it was a perfect fit. Tonight I'll crimp up the inner wing looms but it will be some time before they're needed. And still need to order a fuse box.

Nice one. My Mrs would definitely miss the inches.

Here are my inner wing looms, need to get some more pvc sleeve and the ends on, but will leave this now until the wings are back on. Notice the one purple wire - I forgot one side had the horn so another single Socket is on order. I'm not running earth through any of these connectors, all earths are going to have rings on the end and Bolt somewhere.

A man after my own heart! I'll be making my own looms too, and adding a number of additional cores for extra widgets

Great thread too - watched

I may have said in the past that I actually want a top / bottom opening tailgate setup on this one day (think Range Rover) but Parts supply and cost have put that on hold for a while. Tired of wiring for a bit, I have ripped the crusty bottom skin section off the original rear door to inspect the frame. I was just going to slap a coat of paint on it but now it's going to hang around I thought I'd do a better job.

Skin removed


Few holes in the bottom


Cracks from slamming shut


That bracket almost fell off


This was also not attached any more, such was the rot.


Ive been at it with the grinder, qnd got the bottom section tacked in, more pics to come tomorrow.
Also realised that I don't want my spare on this door as it's a h/d / wolf steel and weighs a fair bit, looks like I'll have to make / buy a separate carrier for that too.......

Discokids said:

I may have said in the past that I actually want a top / bottom opening tailgate setup on this one day (think Range Rover) but Parts supply and cost have put that on hold for a while. Tired of wiring for a bit, I have ripped the crusty bottom skin section off the original rear door to inspect the frame. I was just going to slap a coat of paint on it but now it's going to hang around I thought I'd do a better job.

Skin removed
View attachment 141712

Few holes in the bottom
View attachment 141713

Cracks from slamming shut
View attachment 141714

That bracket almost fell off
View attachment 141715

This was also not attached any more, such was the rot.
View attachment 141716

Ive been at it with the grinder, qnd got the bottom section tacked in, more pics to come tomorrow.
Also realised that I don't want my spare on this door as it's a h/d / wolf steel and weighs a fair bit, looks like I'll have to make / buy a separate carrier for that too.......

Click to expand...

I gave my swing away wheel carrier to an LZ member after my rebuild. Didn't want the spare banging my new door to bits. Haven't had a puncture ever in the Landy....12 years+ Going to fit a standard wheel carrier, make a false wheel out of ply or something and put a cover on it.

That's it - your good lady will be ringing you tomorrow, 'Al, I've got a puncture, where's the spare?'

If I make one I'll have it go across the door and latch on the tub, so it doesn't touch the door at all, futureproof for if I ever fit a drop down gate.

Removal of the wiper motor, no amount of penetrating oil would have shifted this;


Bottom tack on




And this came in the post today, bought on eBay for 99p plus postage. Brand new but about 25 years old judging by the car (Passat?) on the box.



Looks good quality but will research it before fitting.

Discokids said:

That's it - your good lady will be ringing you tomorrow, 'Al, I've got a puncture, where's the spare?'

If I make one I'll have it go across the door and latch on the tub, so it doesn't touch the door at all, futureproof for if I ever fit a drop down gate.

Removal of the wiper motor, no amount of penetrating oil would have shifted this;
View attachment 141766

Bottom tack on
View attachment 141767
View attachment 141768


And this came in the post today, bought on eBay for 99p plus postage. Brand new but about 25 years old judging by the car (Passat?) on the box.
View attachment 141769

View attachment 141770
Looks good quality but will research it before fitting.

Click to expand...

She's happy enough about it. She only has about a 14 mile journey to work. If she gets a puncture, it'll be easy enough to get it off the road she can then give me a bell and I can stick the spare in the back of the Mondeo. If we go further away, it'll just in the back. Just in case.
Central locking kit looks good for 99p I fitted a Hawk one. Works fine and was cheap, but not 99p

So where was I - oh, the rear door. I put a brand new skin on, painted thoroughly inside so as not to contact the steel frame, it also painted heavily.



In primer;


These are the original, completely battered front wings. I've used none of this and have got bits as and when to build a new set.


Which is all here after I've sanded and primed them, one piece is from a military 'fender as the holes show.


This could have been used as it was and was a perfect match but had a few minor issues hard to see here.

I felt stupid getting on the train with it.


N/S wing lacquered. It's since been assembled and fitted with the wiring loom.

As for wiring, here are the fuse and relay panels I decided on. I'm left with a few spare slots, some of which I've pre-wired as perm live / ign live to add basic additional circuits later on in life.



The layout I finally decided on:


Making a bracket:


Wiring what I could before it went in the car:


Stole this on eBay with genuine carlings in it but there was a catch....


It came with half a dashboard and I had to go on the train. I took it into the lav and leant it up while I had a pee. After an awkward silence and stare this bloke said ''I've got to ask - is that a car dashboard?' Then proceeded to tell me all about the Johnny Cash song 'one bit at a time'.
A great song!

Coming along nicely, cant wait for the battery to be connected.