The Ls1 R33 Of Fury

[MBS206]

So, life decided to fill my weekends up a fair bit and I've only just been managing little minutes here and there.

I had been slowly working through the full centre panel for mounting switches, as well as a panel for mounting the fuse panel and relay holders to.

After a few CAD (Cardboarded Aided Designs), I transferred everything to real CAD, and then pushed it through CAM and spent Sunday evening with the CNC Laser cutter.

I had built a couple of months back an Acrylic Bender for this project specifically, and tonight I took the chance to bend the panel up as needed, and mock mount most of it.

Hopefully my spare time, and my body hold up on the weekend, and I'll get this actually in properly. There is two small little bits still to draw and cut for the fuse panel, but they're just as added strength for it, as well as additional mounting points for the relays.

 

[Duncan]

Looks good Matt, great to see some progress.

[MBS206]

Alright, quick update

Switch panel is fully mounted.
Relay/fuse panel is fully mounted.

Wiring to O2 is now run fully.
Wiring from relay to headlights is ran. Just need to run the wiring to the switch.
Indicator wiring is fully run except from the relay to the fuse (Will attempt to load the video of me quickly testing it...) First time the indicators have flashed properly in 12 years...

Power steer from Barra ECU I've found out no need to connect, as it doesn't do any controlling of varying pressure, and I don't need the PS switch feed back for the Barra ECU at all.


So far, off the top of my head for wiring to finalise it all.
Run cables for the speed sensor. But that involves me also mounting a speed sensor. Gearbox doesn't have one, and I never had ABS, so no speed rings I can use for anything. Likely end up finding an AU Falcon output housing from T5 with the speed sensor and wire that in.
Some earth straps and earth points.
run a couple of power cables from fuses to relays...
I will need to run wiring later for a thermo fan, but I'm waiting to do that for two reasons: 1) I don't know the current draw I'll have exactly, as I don't have the thermo yet, and 2) I don't have new heavy enough gauge cable if I end up with a thermo pulling 20 to 25Amp like a few of the thermo's I'm looking at do for the huge CFM they flow.
Will also be adding a horn too, but need to find my horns first. Ha ha

Two other things I will be wiring in too, but not just at this exact moment as I'm going to make up a PCB for this, but I'll be setting up wiring for the windows, and wiring for the electric mirrors.

Just about ready to move on to running the fuel lines, will need to order them up this week or the one after
 

 

[MBS206]

Well, turns out not a lot happened from back then to now, between life again, and working on 3 separate other cars (only one of which was mine, and will now be departing the household soon).

 

So I decided with the whole "don't go outside, it's a cyclone!" Turning in to being not a whole lot, I ventured down to the garage, found a couple of water leaks in the shed (the main one I've already fixed), and then ended up "stuck" as it started pouring rain, and I didn't want to walk back inside in the pouring rain. This meant I ended up taking a look at the Skyline, and trying to work out what past Matt had been upto.

I retraced a few things out from scratch, added the rest of the power feeds in that I needed for the indicators, and headlights. Double checked I'd wired a few things up correctly (and worked out how I wired a few things to begin with), updated my sparse notes. Added one of the ground points. Oh, and got really really dusty, as the car is quite dirty.

Wrote up quickly what should be left for me to do with the wiring too.

Adding the below photos more for my records than anything else. I need to make myself a proper book for the car that details everything, and how I've done it, but for now, this is my records...

The third image is my most important one for me, and I need to draw it out into a proper schematic eventually.

The last photo is my re-written list, I'd have put it on the white board, except I had to take the white board down to fix one of the water leaks.

[MBS206]

Yesterday's day in review:

All the wiring to the lights up the front how I want it, is ran, terminated, and all to length.

The only lighting up front I haven't finished is the side indicators, as I need to get to the partly cutup factory loom, and find the plugs for them.

Interesting note, the side indicators use the exact same plug that's in the doors for something else that I don't remember what it is... So that plug better be careful...

 

Power steering solenoid, on the R33 is variable, and from memory PWM. The Ford's control from the docs I have so far, is it's just a on or off control. So I'm not sure it's what I want, and in any case, power steering running, but at its heaviest (solenoid off) is likely what I'll want anyway, so I'm not yet touching it at all.

All the wiring I can complete so far, is done. There are 3 wires I need to make a plug for at the ECU, and these are just for the vehicle speed sensor, of which I need to get a T5 from an AU, so I can use its output that has the speed sensor on it. (My car doesn't have ABS, otherwise I'd set it up to use one of the ring gears on that).

I need to buy new headlight globes and front parker globes, otherwise I could show photos of lights working.

Current fuel lines in and out on this motor are "5/16". I'll order hardline, and some AN fittings for that, and I just need to 100% check fuel line size at the tank end, to get the ends for it.

I'm also looking at a few options for the banjo bolts to AN fittings for the power steering rack. I'll pull the reservoir off the Barras PS pump. There's an off the shelf fitting for that pump for a -10 AN feed, and it'll use a 16mm to dash -6 an outlet to feed the rack. I'll be making my own power steering reservoir, I'm going through the thought process at the moment of how I'll run the baffles, and I need to research another idea for it too.

Edited March 14 by MBS206

[MBS206]

Update from today;

Hard work was completed today behind a computer... Ha ha

Hardlines for new fuel lines ordered, and fittings for it to connect up too.

Banjo fittings for owner steer ordered too, will be AN fittings.

Ordered all the weld on fittings I need to build the PS reservoir too. Only things I'll need left for power steer is a couple of off the shelf fittings for the pump, and to build 3 lines.

[MBS206]

Well... New things have arrived...

And now I need to really dig into the design of the power steering reservoir.

 

 

[MBS206]

It's about time I start work on my sun tan. So I knocked up a few parts that will all combine together to become my new power steering reservoir. Now just to produce an abundance of UV and IR rays while melting a heap of bits of alu to become one... Well, that's after I put one more hole in it for the return line to plumb to.

It likely won't be this weekend, as Sunday I'm meant to be in doing some last minute stuff to the AMG race car, and the weekend after will be filled with non my Skyline stuff, followed by Bathurst 6 hour. So I don't expect to get to melt metal for at least 3 weeks.

 

I also managed to stuff up and start cutting the hole for the res to pump pipe on the wrong side of the line... It means instead of the lines being nice and tight against the inner guard, they'll be out off the guard. 

 

The size of it means I should end up with about 1.8L of power steering fluid, and still have space for another half a litre before it reaches the overflow/breather. This is wayyyyyyy more capacity than factory, which should help keep Powersteer oil temps lower, and the design hopefully allows it to prevent any aerated oil being able to makes its way down to the bottom as it'll have a couple of baffles and some hopeful trickery to force air bubbles away from the bottom.

[MBS206]

Well, I managed some time today and did start some of the welding on the PS Res. Absolutely no photos at the moment as today has confirmed what I've known for a long time. I need a LOT of practise welding aluminium... TIG is new to me... So yes, my welds are going to be butt ugly, and that annoys me and my perfectionism. Hence, no photos.

When I did my design, my brain put together a backup plan in the event I couldn't reach properly inside to weld it... And I can't reach properly inside to weld it, so I need to enact my backup plan, which means I need to cut the main tube...

The only powered saw I have big enough to cut 100mm diameter tube, is my big band saw and it needs an overhaul and new band put on, as it won't cut straight (And has wayyy too high of a TPI for alu anyway).

The original cut that I did yesterday to cut it down to 350mm length I did by hacksaw. Let me tell you, the not overly active guy, with ADHD nearly started three different projects while cutting through that pipe, and today, my back and arms are killing me for trying to be active... So I've decided I'm NOT pulling out the hacksaw today to chop it down... 

[robbo_rb180]

Good you making progress with this rig.

Aluminium welding is painful to learn, have you got a pedal as I found it so much easier with one.

If that's the AMG I think it is, you would working with Benny?

[MBS206]

47 minutes ago, robbo_rb180 said:

Good you making progress with this rig.

Aluminium welding is painful to learn, have you got a pedal as I found it so much easier with one.

If that's the AMG I think it is, you would working with Benny?

Yep, I got the pedal, it was a huge thing I made sure I got for it. I have the CigWeld 205ACDC, with all the parts for it.

Yes, Benny is good friends with Tony who owns it. I work across the car park from it. We presently have the Clio in our workshop.

I met Benny for the first time a couple of weeks ago, nice guy! Was he at MSR with you? I know he worked recently on one of the V8s entered in as a wildcard.

[robbo_rb180]

1 minute ago, MBS206 said:

Yep, I got the pedal, it was a huge thing I made sure I got for it. I have the CigWeld 205ACDC, with all the parts for it.

Yes, Benny is good friends with Tony who owns it. I work across the car park from it. We presently have the Clio in our workshop.

I met Benny for the first time a couple of weeks ago, nice guy! Was he at MSR with you? I know he worked recently on one of the V8s entered in as a wildcard.

Yep he is an awesome bloke, we work together on that car.
You will have fun at the 6hr, Tony doesn't stuff around when he goes racing does pretty well.