1994 - Ford Escort Cosworth - power steering fluid tank

[jonomisfit]

I dug out a spare sheet of plywood to help me out

P1030867 by jono_misfit, on Flickr

roughly pinned on the loom

P1030868 by jono_misfit, on Flickr

started laying it out a bit

P1030869 by jono_misfit, on Flickr

and some more

P1030870 by jono_misfit, on Flickr

then started lining out to juntion and connections

P1030871 by jono_misfit, on Flickr

P1030872 by jono_misfit, on Flickr

started identifying some other un-needed wires and pulled them back

P1030873 by jono_misfit, on Flickr

The black line on the left hand side shows the additional length needed to get to where I need the cables to be for the centre mount console.

finding some more unneeded cables and pulling back and coiling back at the fusebox connector.

P1030874 by jono_misfit, on Flickr

P1030875 by jono_misfit, on Flickr

the big un-sorted buch of wires are mainly the radiator fan wiring / relays. These used to sit next to the battery, but my battery is inside the car, so i'll be re-wiring these to be fed from the centre panel.

P1030876 by jono_misfit, on Flickr

[jonomisfit]

I'm sure these pictures are all blending in to one for a lot of people, but more wiring.

Tracing back and tagging everything.

P1030877 by jono_misfit, on Flickr

I picked this up off EBay. Not completely correct, but correct enought to help me considerably.

P1030878 by jono_misfit, on Flickr

due to these.

P1030879 by jono_misfit, on Flickr

slowly whittling it all down to the bare minimum.

P1030880 by jono_misfit, on Flickr

I've removed some things that I may actually put back in some form, like the heater front screen control.

there are also a few things that I'm going to re-route as they go completely round the houses to get places.

P1030881 by jono_misfit, on Flickr

there are a lot more wires on the left hand side, and everything coiled up isnt needed... hopefully.

P1030882 by jono_misfit, on Flickr

there were also some things missing, so i've added them in. Most notably the starter motor feed line.

P1030883 by jono_misfit, on Flickr

I'm also going to be bringing the live feed (after the cut off switch) to an insulated bulkhead post, to pass a main feed directly into the engine bay. This will give me a handy connection point for starter motor / alternator, and also a reasonably easy access jump point if ever needed.

P1030884 by jono_misfit, on Flickr

I'm also going to make use of the spare port on the passenger side of the bulkhead and shorten some routes to the fuse panel. Especially where i'm running in new connection (like the red wire above), or adding a new connection that on that side of the car.

[Deleted]

Ok I going to stop looking - its giving me a headache

[jonomisfit]

After a bit of a wait due to coronavirus's impact on thing my custom top mounts turned up today.

P1030885 by jono_misfit, on Flickr

custom mounting arrangement and the spherical is sized as a direct fit to the struts mounting shaft rather than spacers. This has allowed the biggest spherical that can reasonably fit in the hole I have.

They arent the genuine WRC top mounts, as they are 3x the cost and need about £1500 per corners worth of other suspension bits to work. At some point maybe, but these will get me on the road.

Thought i had best check I hadnt messed up any dimensions.

P1030887 by jono_misfit, on Flickr

Fits perfectly. I put nylon washers on as I didnt want to scratch it whilst tightening up in case I needed to send back!

P1030888 by jono_misfit, on Flickr

It also clears the bonnet

which was a concern....

P1030886 by jono_misfit, on Flickr

I need to make up a couple of conned spacers to allow the joint movement, then I can fit the struts and see how it sits.

But I cant get in to the lathe as there's another job in the way...

some other bits turned up for the wiring loom.

high temp braid sleeving

P1030889 by jono_misfit, on Flickr

in a few sizes

P1030890 by jono_misfit, on Flickr

I did a load of digging round and ended up going to PMG. Ebay prices were bonkers and the same price as a 1m length from EBay there was abot a 10m roll.

so having determined I've got what I need from the car loom I started removing anything not needed and buching by funciton on the car side of the bulkhead connector.

P1030891 by jono_misfit, on Flickr

I then started looking at the dashboard wirring

P1030892 by jono_misfit, on Flickr

which is loaded with bodges.

P1030893 by jono_misfit, on Flickr

A number of which seem to be polarity inversions for whatever reason.

I need to buy a load of wirring products, but they'll have to wait until after pay day.

[legend]

wiring is a mystery to me, but between this and the Binky show it's starting to become a little clearer

[jonomisfit]

not many picture, an no exciting pictures, from today. All wirring related.

stripped the binding from the dash loom and started working out what most things are. There were some complete anomolies that werent in the wirring diagram and looked like factory loom additions, which makes me think they are the escort cosworth guages (boost etc.) that arent in the standard loom.

P1030894 by jono_misfit, on Flickr

having gone through it all, i then realised, there's only a couple of bits i'm acutally interested in

P1030895 by jono_misfit, on Flickr

none of these!

The onyl bits i'm intersted in are those that connect to the column switches (and then only if I can find a way to mount them onto the column as I'm using a sierra column not an escort one), plus the cabin blower wirring. The rest is spare. I marked up anything I cut should I ever have the need to rebuild the loom.

then moved back to inside and started final config of the rear of car wirring.

labled everything

P1030896 by jono_misfit, on Flickr

then pulled back the heater rear screen feed (as it wont be used) and re-routed as a second fuel pump feed.

P1030897 by jono_misfit, on Flickr

ran in a new live feed, and pulled back from the dashboard end the fuel sender wires and routed them all (plus an earth) to just above the rear turret where the guage will mount. This will be visible through the rear quarter when filling the car. With the amount the car will be used and what it will be used for, its more usefull to see the fuel level when filling, rather than when driving.

P1030898 by jono_misfit, on Flickr

Its a reasonbly common rally car trick and I'll make a small mount that goes between the cage backstay and the diagonal brace.

then started straightening and binding with tape the rear loom.

P1030899 by jono_misfit, on Flickr

P1030900 by jono_misfit, on Flickr

P1030901 by jono_misfit, on Flickr

this is with the aim of starting to fit the braided sleeving next week... If my de-pinning tools arrive....

[jonomisfit]

In an entirely unexpected turn of events my de-pinning tools have not turned up yet. No doubt they will arrive on monday....

Centre console will be tight for space so I've been at looking at other options for button mounts.

P1030902 by jono_misfit, on Flickr

May well mount the ignition switch and start button here.

The i figured i needed to make some things.

Ali bar

P1030903 by jono_misfit, on Flickr

cut to length and attach with the lathe a number of times.

P1030904 by jono_misfit, on Flickr

gave spacers

P1030905 by jono_misfit, on Flickr

P1030906 by jono_misfit, on Flickr

these are just mock up ones, the actual ones will be in a decent steel but I'm also waiting on that arriving...

old strut to remove

P1030907 by jono_misfit, on Flickr

new strut in.

P1030908 by jono_misfit, on Flickr

a bit of a different in damper rod size....

fitted and top mount temp bolted down

P1030909 by jono_misfit, on Flickr

I think i need to relieve it fractionally just where the strut brace mount is

looks like so in

P1030910 by jono_misfit, on Flickr

and other side in

P1030911 by jono_misfit, on Flickr

i tried with the bonnet shut and there are milimiteres between the damper rod and the bonnet, but its clear.

P1030912 by jono_misfit, on Flickr

I ran out of time to fit the rears, so first job on Sunday.

[peteh1969]

John

Do you mean "Performance Shims" Rather than Spacers?

Nice work.

[jonomisfit]

Rear dampers / coilovers fitted

P1030913 by jono_misfit, on Flickr

I'm going to have to do some mods to the rear arms to clear the dampers properly. I hacked a few bits off just to get them on, but will be tidying up and making proper return flanges.

P1030914 by jono_misfit, on Flickr

P1030915 by jono_misfit, on Flickr

the reason for the clashes is I've got Group A rear dampers which normally go into the magnesium rear arms and the mount is a lot shallower. I can get round this by trimming back the steel arms I've got and making some tweaks.

My cheap set of de-pinning tools turned up

P1030916 by jono_misfit, on Flickr

you insert them into the Junior timer conectors and they push the pin latch down allowing you to withdraw the pin.

P1030917 by jono_misfit, on Flickr

I practiced on some of the spare conenctors to try and get a technique priot to doing this to ones that actually matter...

P1030918 by jono_misfit, on Flickr

I managed with the junior timer connections without issue, but I just couldnt get the junior power timer pins out without wrecking the connector. Rather than risk it on the car i'll buy a propper removal tool and see if that makes the difference.

Better start on the bits of the loom i can do without de-pinning. Number plate light.

P1030919 by jono_misfit, on Flickr

nylon braid marked out to length

P1030920 by jono_misfit, on Flickr

tape applied to stop it freying once cut

P1030921 by jono_misfit, on Flickr

I used the de-pin tool to removed the connectors and fed the cables through.

P1030922 by jono_misfit, on Flickr

P1030923 by jono_misfit, on Flickr

P1030924 by jono_misfit, on Flickr

heat shrink onto ends.

P1030925 by jono_misfit, on Flickr

I use the heat shrink wich has a film of heat activated glue on the inside. This seals it to the braid and the cables. Stops the cables pulling through unwantedly.

Mrs_Misfit has every gadget know to the human race... include one of these little lable makers.

P1030926 by jono_misfit, on Flickr

I bought some yellow lables and some heatshrink tube labels for it and tried it out

P1030927 by jono_misfit, on Flickr

make up my own code for things....

P1030928 by jono_misfit, on Flickr

gives a little lable

P1030929 by jono_misfit, on Flickr

fitted, then clear heat shrink over the top to protect it

P1030930 by jono_misfit, on Flickr

P1030931 by jono_misfit, on Flickr

completely and utterly excessive, but at least I should know what things are in the loom now....

rear fuel guage wiring

P1030932 by jono_misfit, on Flickr

P1030933 by jono_misfit, on Flickr

then did the fuel pump feeds and earth lines

P1030934 by jono_misfit, on Flickr

then did the cross car sheathing

P1030935 by jono_misfit, on Flickr

and applied some heatshrink to the bunch splits to hold it all firm

P1030936 by jono_misfit, on Flickr

I did the run that goes to the first rear light split (but then got stuck as need the de-pin tool), the fuel sender, and started setting up for the run to the front of the car.

P1030937 by jono_misfit, on Flickr

Hopefully i've got my wiring right :-)

[petervdv]

Nice attention to detail with the labels

[samta22]

^^^ What he said.

Excessive? Possibly. but a great idea and has got me thinking about my loom I'm playing with that the moment... I have one of those machines hiding somewhere too.

[melle]

Great work as usual!

I can highly recommend Laser terminal tool no. 3932 (I have three!).

Are you aware you can get heat shrink that you can print on?

[jonomisfit]

Thanks. Entirely excessive just how I like it 😁

And cheers for the links.

The yellow labels I'm using are heat shrink, however tests ( read fitting over cables) showed it rubs off a bit, so the clear tube protects the text.

I'm also limited on diameter of lable heatshrink by the machine so some need to be labels and the clear heat shrink keeps in place.

[melle]

Hah, looking at your photos again I now see they're sleeves, not labels. Makes sense to fit the clear tubes over them.

[jonomisfit]

Its a mix, really but it does what I need :-)

continued on with the loom work

P1030938 by jono_misfit, on Flickr

P1030939 by jono_misfit, on Flickr

still some break out labelling to do.

P1030940 by jono_misfit, on Flickr

P1030941 by jono_misfit, on Flickr

back in the car for a final check that it lines up where needed

P1030942 by jono_misfit, on Flickr

nicelly keeps it all out the way

P1030943 by jono_misfit, on Flickr


I'm now waiting for my new de-pinning tools to arrive to finish off the back end, and my bulkhead connectors. Hopefulyl they are both here before friday.

I need to get back onto the center console design so I have something to wire to....

[jonomisfit]

My selection of actual depin tools arrived today.

They actually work. I found the right one, push it in firmly, and out pops the pin.

Success.

This will give me chance to finish the back of the loom covering on the weekend.

[darrenh]

back the loom weaving truck up a second, you can get clear shrink wrap ?

[legend]

Jul 8, 2020 19:38:01 GMT jonomisfit said:

My selection of actual depin tools arrived today.

They actually work. I found the right one, push it in firmly, and out pops the pin.

Success.

This will give me chance to finish the back of the loom covering on the weekend.

can you post a link to the tools?

[jonomisfit]

Yep. I just got some from eBay in a range of sizes. It feels a different material to normal heat shrink but I may be imagining it.


I just got a cheap set of tools from eBay, but they appear to work.

www.ebay.co.uk/itm/313121325043

[jonomisfit]

rear light sleeve added

P1030944 by jono_misfit, on Flickr

cross car, and being wholly excessive... earth wire braided sleeve applied

P1030945 by jono_misfit, on Flickr

P1030946 by jono_misfit, on Flickr


entirely over the top labelling... just in case I cant remember the brown wires on the rign crimp are in fact ground....

P1030948 by jono_misfit, on Flickr

P1030949 by jono_misfit, on Flickr


clear heat shrink for those that were interested.

P1030947 by jono_misfit, on Flickr