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FROM HERE ONWARDS THE PICTURES ARE BETTER QUALITY USING A
NEW DIGITAL CAMERA .
ONCE THE BASIC WIRING IS IN FOR THE FRONT WE CAN START TO FIT THE LIGHTS AND
INDICATORS. ALSO FITTED THE PORSCHE BADGE ON BONNET. NOTICE THE SLOT CUT OUT
OF THE LOWER PART OF THE BUMPER, THIS IS FOR AIR FLOW TO THE TWIN FAN FRONT
MOUNTED RADIATOR.
Note: THIS IDEA WAS LATER SCRAPPED AS REAR MOUNTED COOLING
SYSTEM IS FAR MORE EFFICIENT THAT THE RADIATOR AT THE FRONT.... LEARN BY
OTHER PEOPLES MISTAKES...YOU HAVE BEEN WARNED. |
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RE-ROUTING THE WIRING AND ADDING MORE AS I GO ALONG. A GOOD TIP HERE IS TO
ALWAYS KEEP ONE WIRE IN THE SILL AREA TO ACT AS A DRAW WIRE AS IT MAKES IT SO MUCH
EASIER. |
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NOTICE THE CUT OUT SECTION AT THE REAR BEHIND WHERE THE SEATS
WILL GO? THIS IS FOR ACCESS TO THE DISTRIBUTOR
ON THE CVH ENGINE. FAILURE TO DO THIS WILL RESULT IN NOT BEING ABLE TO CHANGE
THE DISTRIBUTOR CAP ETC.
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IF YOU LOOK CLOSELY YOU'LL NOTICE AT THE TOP RIGHT
OF PICTURE IN THE CORNER OF WINDSCREEN AREA A CABLE TIE FASTENED ON TO
THE WINDSCREEN WIPER SHAFT, THIS IS TO SIMULATE THE SWEEP OF THE WIPERS WITHOUT RISK
OF DAMAGING THE PAINTWORK. THE WIRING UP OF THE WINDSCREEN WIPERS TOOK THE
LONGEST TO DO AS THERE WERE SOME PROBLEMS. . . BUT MORE OF THAT LATER. |
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HERE WE HAVE THE HEADLIGHTS AND INDICATORS FITTED, YOU CAN SEE AT THE BOTTOM
RIGHT THE WIRING FOR THE ELECTRIC FANS FOR THE RADIATOR. |
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THE EARLY STAGES OF TESTING OUT PARTS OF THE ELECTRICS,
WITH A BATTERY INSIDE THE CAR FOR FAST DISCONNECTION IN CASE ANYTHING NASTY
OCCURRED. THIS IS WHEN IT GOT TRICKY CONVERTING THE WIRING HARNESS
FROM FORD TO MY OWN HOME MADE BITS, THEN TO VW GOLF WITH PORSCHE SWITCHES & VW VARIANT
WIPER MOTOR ADDED TO THE PROBLEM. THAT IS THE REASON FOR THE TWO A4 SKETCHES NEAR THE COLUMN
SWITCHES AS USING 4 WORKSHOP MANUAL DIAGRAMS GOT A LITTLE CONFUSING SO I MADE MY
OWN. THE MAIN PROBLEM I HAD WAS GETTING THE INTERMITTENT WIPE TO WORK. BUT THAT WAS
SORTED OUT LATER. |
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FOLLOWING MANY HOURS TRYING TO
GET THE WIPERS TO WORK CORRECTLY I WAS FED UP WITH THE WIPER WIRING SO I HAD
A BREAK AND STARTED THE BACK END ASSEMBLY. STARTING TO LOOK GOOD ? THE BACK
LIGHTS WAS THE EASIEST JOB OF ALL BUT ALL THE CONTROL SIGNAL WIRING TO THE
ECU COMPUTER AND MANAGEMENT WAS A BIT OF A JOB, STILL IT WENT TOGETHER
WITHOUT TO MUCH TROUBLE AND I FOUND THE CUT OUT ACCESS SECTION FOR THE
DISTRIBUTOR INSIDE THE CAR WAS A BIG HELP IN CONNECTING UP SOME OF THE MORE
AWKWARD SENSORS TO THE ENGINE. |
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WELL IT WAS TIME TO GET BACK TO
THE DREADED PROBLEM OF THE WIPER SWITCHES. AFTER
A LONG TIME SCRATCHING MY HEAD I FINALLY TRACED THE PROBLEM TO BE A
CONTACT INSIDE THE SWITCH THAT WAS DEFECTIVE AND SENDING A LIVE FEED DOWN
AN EARTH WIRE RATHER THAN THE WIRING, THIS
WAS CHANGED FOR A NEW SWITCH AND "HOORAY" IT WORKED, INTERMITTENT
WIPE, SINGLE SPEED WIPE AND STORM SPEED WIPE . . . . . LOVELY...... THE LESSON
HERE IS SIMPLE. NEVER RULE OUT A FAULTY PART. |
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HERE IS A VIEW OF THE ACCESS POINT
FOR THE DISTRIBUTOR INSIDE THE REAR OF THE CAR BEHIND WHERE THE SEATS WILL
GO. AS YOU CAN SEE I'VE STARTED TO ADD THE STAINLESS STEEL BRADED
HOSE'S FOR THE FUEL. COOLING SYSTEM & TURBO BOOST CONTROL LINES. THE SILVER
MATERIAL YOU CAN SEE ON THE EDGE OF THE HOLE IS A FIRE & CHEMICAL RETARDANT
MATERIAL MADE FROM STAINLESS STEEL FIBRE WOVEN CLOTH AND
I LINED OUT THE WHOLE ENGINE BAY WITH IT. |
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ENGINE BAY LOOKING A LITTLE
DIRTY BUT THAT IS SOON TO BE CHANGED. HERE WE CAN SEE THE LOCATION OF THE EXPANSION BOTTLE FOR THE COOLING SYSTEM.
ALSO YOU CAN SEE THE BRADED HOSE'S FOR THE COOLING SYSTEM AND AT THE BOTTOM
CORNER, THE FLEXIBLE HOSE LEADING TO THE PIPE WORK UNDER THE CAR. |
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VIEW SHOWING THE BRADED HOSES.
YOU CAN ALSO SEE MORE WIRES WAITING TO BE CONNECTED, THESE ARE FOR THE REAR
WASH WIPE, REAR FOG LIGHTS AND ENGINE BAY LIGHTING. (AN OPTIONAL EXTRA
I PUT IT). |
