Andyrews Progress Thread, 1/16/22 A Trip to The Red Barn - Lets fab a Firewall! Options

[Andyrew]

The video is a bit missleading, I was going a solid 85%, leaving 15% on the table for the fact that I really didnt want to spend 6900 euros if I wrecked it, and that it was still pretty wet out.

I also limited my speed to 100mph, as I found that to be a factor for major crashes in my hundreds of test laps on simulators and research. Even with all of that many corners suprized me, I am closer to knowing the track but no where close to knowing the correct line.

[Andyrew]

Looks like a fun trip! Glad you made it back OK. I haven't been there in 20 years and need to go back with my wife.

You only have 2 weeks to be ready for WCR. Better hurry!!!

Technically still in France... (We actually heard a french couple say Oh HoHo! today, Jerika said life goal achieved when we heard it)

[Andyrew]

Been working on wiring the past week. I needed some different connectors on a couple of my sensors so I soldered the new connectors on.

Sadly it looks like I need to extend the harness a bit.


Luckily I have a spare harness to pull from.


Supplies came in as well to tackle this (IMG:style_emoticons/default/smile.gif)


Also got the shifter mounted (IMG:style_emoticons/default/smile.gif) yes its crude. Its temporary until I get the center console built.


Video of action. Loving the location

https://www.youtube.com/watch?v=2yz_uBNnIPE



Ill be getting some help this weekend (IMG:style_emoticons/default/smile.gif) anyone in the area is welcome to swing by!

[Mueller]

Nice progress there....

Sorry, I cannot make it, I am still in North Carolina....

[Andyrew]

Had a bunch of help yesterday, especially from Mike Bellis!


He spent all day extending the wiring harness until exhaustion took over and I finished it up last night at 1am.



Im amazed at how much I learned just watching him..

Im going to see about finishing up taping and locating the dash harness tonight.

Also fixed the leaking coolant line and tested the system, everything seems to work great! But I still have to wire up the controller for the water pump. Ill do that after I mount the dash harness.

[dan10101]

Looks Good! Thanks Mike for helping him out!

Darla isn't helping much though...

[Andyrew]

Last update for the month.

WCR last weekend was a blast!! The rock solid Fiesta ST was a monster on the autox and just flew around the mountain roads!


But enough about that... Progress was slow due to WCR/Work/Home duties.

The goal for next month is to have the engine running and the car drive-able!
Be sure to stay tuned.

I was however able to put a couple hours in to do some wiring. Laid the harness out and routed the positive cable from the battery to the relay box. Ran a really nice 2ga wire with some lugs that I soldered. I've got 6 more lugs and another 15ft of cable so we'll see if I use it anywhere else! Not pictured is a 250amp fuse that just came in the mail last night that I'll mount to the center tunnel in line with the main power.

Not pictured is a solution for the wires coming through the body into the engine bay. Currently a square hole and the wires are protected by some coolant hose. I have the original harness loom ECU box that I have cut up and I think will work nicely after some fanangling. It's still going to take a bit to finish up...

[Andyrew]

Working mounting the wiring.

Also figured out the throttle stuff (IMG:style_emoticons/default/smile.gif)




Its actually pretty much in line with the OE throttle pedal. If I could find it I might even be able to use it..


Also started mounting the wiring. Got the main relay harness mounted, this is where the fat battery lead goes.


Also mounted the fuse box. I like it in this position. The panels will be easily removable so this can be accessible easily.

Im going to finish mounting the wiring tonight, hook up the ECU, put power to the system and see if I can connect to the ECU. I currently have a bunch of relays missing but thats just a pick n pull trip tomorrow morning if I cant get power to the ECU.


From there I will need to mount the dash cluster, mount a couple of my stanalone guages, wire up the water pump and boost controller, and wire up all the lighting.

I also dont know where the plugs are for the clutch/brake so I will have to research that. Its an automatic harness so I might need to do some wiring.

[Andyrew]

One last fun thing (IMG:style_emoticons/default/biggrin.gif)

[dan10101]

The wiring looks really good! Not so sure about the gas pedal... (IMG:style_emoticons/default/evilgrin.gif)

[Andyrew]

Gas pedal is mock up to help me determine position and length. (IMG:style_emoticons/default/smile.gif)

The shaft will have a welded piece of steel to form the pedal similar to the current layout and I will either bolt on an aftermarket pedal or just rubber coat the steel.

[dan10101]

Gas pedal is mock up to help me determine position and length. (IMG:style_emoticons/default/smile.gif)

The shaft will have a welded piece of steel to form the pedal similar to the current layout and I will either bolt on an aftermarket pedal or just rubber coat the steel.

Looking forward to seeing your work. You impress me with your ingenuity.

I have to weld up some recessed brackets for the 944 seats. It's going to get ugly. They sit to high unless I leave the sliders out. Still they are nice seats and I can fit my fat butt in them. Always a good thing. So no sliders or sliders, I'm keeping them.

Since I brought it up, here's the seat I'm using. http://www.jegs.com/i/Scat/942/80-1606-61L/10002/-1

[Andyrew]

I've seen your welds, It'll be fine (IMG:style_emoticons/default/smile.gif)

Why not cut out your factory brackets and bolt the sliders to the floor? I welded on some stubs for my sliders for the drivers seat onto the floor and I really like how it turned out (IMG:style_emoticons/default/smile.gif) (Pretty sure its the first page in this thread...)

[dan10101]

I may have to. But they are about an inch inside the factory mounts, I may be able to recess the mounts and keep the factory seat mount locations. I'm not opposed to cutting out the factory mounts but I want to try this first. I just need to get it done before the hill climb. I hope it cools down so I can get some work done.

[Andyrew]

Extended the wires to the brake and clutch switches.



Redid the mounts for the sensors, this should get me a bit more foot room aftwr I make a new cover for it. It also keeps it on the pedal cluster.


I need to grab a couple relays and wire up the fuel pumps.

[Andyrew]

Got a little bit of progress done,



Hooked up the ECU and got proper readings! Which means that the wiring job seems to be correct.

Pulled the spark plugs and put a little bit of oil down them as well as filled the engine up with oil and tightened the oil line.

I tried to crank the starter but it wouldnt do anything. After discussing it with my Audi buddies, its because I do not have the central locking system hooked up. I just need to ground the wire going to the central locking system.


So in the meantime I hooked up a test wire to the starter and then set it on the battery post to test to make sure the starter worked. Yup! So I gave it a good couple of 30 second cranks to start to prime the oil system and get the lubrication of the engine going good and ensure there was no strange noises. Everything seemed good!

Next step is getting the fuel working, a couple more little things and start this mama jama (IMG:style_emoticons/default/smile.gif)

[Chris H.]

Awesome. Nothing more exciting than when it fires up. If you have the electrical right it will (IMG:style_emoticons/default/beerchug.gif) .

[76-914]

Awesome. Nothing more exciting than when it fires up. If you have the electrical right it will (IMG:style_emoticons/default/beerchug.gif) .

Uh, that's #2 on the list, Chris. Numero uno es when the ECU Fires and goes up in smoke. Andy, I'd be interested in your pre start diagnosis of your wiring job. In detail if you've time. I don't mind telling you that when I powered up mine the first time I was so nervous you couldn't have driven a ten penny nail up my ass with a sledge hammer. Kent

[Andyrew]

Well, I double checked to make sure there were no loose /exposed wires, I read and re read how the system gets its power, and I hooked up my power wire accordingly.

I grounded all the grounds and installed all the relays per the manuals and what I found on the cars in pick n pull.

I left the key off and hooked up power to the system and inspected everything for hot or melting wires, then I hooked up the ECU and turned the key to the on position. Since I dont have the ABS hooked up the dash cluster beeped at me three times (The tuner said he turned that off.... but alas..) I then plugged in my ecu logging software and pulled up the ecu as well as any parameters that it could read at the moment. I also checked fault codes, but my software being the free version basically wouldnt let me check everything, so I left it at that.

[Chris H.]

What usually causes a melted wire is accidentally electrifying a ground wire. I did it. Luckily it wasn't connected to anything important so I just replaced it. The melting started IMMEDIATELY. Within about 10 seconds the garage was full of magic smoke. I think you're clear of that hurdle.

I think you're in really good shape. You're getting readings from the ECU, everything powered up so its grounded correctly. Time to button up the fuel stuff and fire it up!