Author Topic: Stupidity in a Suzuki SJ - non VAG idiocracy. (Read 42508 times)

Diamond Hell · « **Reply #50 on:** 18 March 2012, 19:46 »

Errrr, this was in general off-topic.

Then it was moved to here, which is why you might have seen something similar before.

Diamond Hell · « **Reply #51 on:** 23 March 2012, 00:04 »

Rear tow point sorted:

Fuel tank nearly there, ready to be mounted:

Cut-off in front of windscreen:

Ready to be wired in, using an Audi 100 power feed I've had lying about for years.

Now into the jobs that seem to take FOREVER!

While I was sorting that, Mike wired in a 'convenience' relay kit for the indicators on the Passat, which was nice.

He's a star.

Diamond Hell · « **Reply #52 on:** 27 March 2012, 08:45 »

Got a crafty couple of hours at Wellow Racing last night, after dropping in to Newey & Eyre at lunch to pick up a couple of ring crimps. Mike, who shares the barn's Dad is an electrician so has proper crimping pliers for the crimps. We now have properly done ends on both power cables, which is nice.

The electrics have needed to be modified to suit the kill switch as well. Thankfully the SJ doesn't have terribly complicated electrics. The modifications have extended to moving the positive feed from the main loom, to go to the starter, then taking the positive feeds in the main loom to the big positive terminal on the kill switch. In addition to this the ignition switch wires now go to the kill switch and back and there's a ballast resistor that goes on the second pair of the terminals and to earth.

I had no idea a ballast resistor was needed in this situation, but because we're breaking the positive, not the negative (I think) we need something to maintain current for the split second the circuit is broken, to prevent the alternator topping itself. Or some such story; I just drew the wiring diagram while nodding and listening to the theory.

Last night was the first time I've had the opportunity to use a pair of ratchet crimps for the small electrical terminals. This has left me fairly disgusted and wondering why I didn't buy one of these crimping tools before. Oh hang on, that'll be because I'm tight and they're over £20 for something I won't use THAT much (actually I will and I have fairly clearly been fooling myself).

It's one of these and if you don't have one and you have electrical connectors which you might use, go buy one: http://www.screwfix.com/p/forge-steel-ratchet-crimping-tool/70036

Next up, I should probably go buy a pair of these: http://www.tooled-up.com/Product.asp?PID=187607

golf-sib · « **Reply #53 on:** 27 March 2012, 20:31 »

Them crimping tools are brilliant, had a set at my old work place when working on PCB's.

I've never used them wire strippers before, but I have these: http://uk.rs-online.com/web/p/automatic-wire-strippers-accessories/2968194/ They are fantastic for use, again I used them a lot when working with PCB's and absolutely love them

Horney · « **Reply #54 on:** 29 March 2012, 12:49 »

Ratchet crimpers are the dogs danglies. I alos use one of these for wore stripping:

http://www.tooled-up.com/Product.asp?PID=17363

love it!

Nick

Diamond Hell · « **Reply #55 on:** 01 April 2012, 18:05 »

Grabbed a couple of hours this afternoon, after collecting a couple of metres of the correct-sized fuel pipe yesterday.

Fuel tank now has a breather in it and the return has the banjo with copper washers (also picked up yesterday).

It's bolted to the floor with four M8 bolts. The breather goes through a non-return valve and vents below the floor, the two fuel pipes go down through the floor, to the original fuel hard lines.

As it was all hooked up, with a new fuel filter, I figured I may as well drop some fuel in and see if it'd start, which it obligingly did, on first (albeit long) turn of the key - from dry!

I even took it up the track to make sure it ran OK, which it did - no windscreen so it's a particularly refreshing ride!

So, next Sunday is a 4x4 trial. Not sure who's going to be driving it, but it looks like Mike and I as a minimum.

Diamond Hell · « **Reply #56 on:** 06 April 2012, 19:56 »

Had a couple of jobs to sort today, from one of the club's experienced scrutineers:

Wood cap on the battery - if it winds up upsidedown it should contain the acid in the (sealed) battery. Gotta love regulations.

Steering column lock disabled. Can't ever remember a steering lock coming on, but hey - steering lock securing bolts punched loose and swapped for allen-headed bolts once the locking pin had been disabled.

Final thing to do - fit the new LED lights to the trailer and we should be ready to head off to the trial.