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Old 04-15-2018, 11:16 PM   #476
remski
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The beginning of the 3 day weekend.



So it begun. The final phase of the engine harness.
Here its all pinned and ready for the connectors
.



To shield or not to shield.
Mapping out the shielded pins so they match with the wiring inside.




Poof and one of them is done.



Needed to take a break from all this wiring, so it was time to power up the ECU for the first time.



Its been in the closet for few years.. so first order was a firmware upgrade.



Cant really tell why the harness is taking so much time.
Here its all epoxied out for the day and left to dry overnight.

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Old 04-16-2018, 02:26 AM   #477
illuminaugty
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Quote:
Originally Posted by remski View Post
Harness work moves on..
My virgin AS connections with service loops !!!




Now mounted with a boot.
Loving how clean these connectors are looking on the firewall. Nicely done!
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Old 04-17-2018, 02:55 PM   #478
mcursch88
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Crystal black silica

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Quote:
Originally Posted by remski View Post
I would guess cnc... and were trimmed on the lathe.

I'll ask when I pick the car up.
this would have been done with a vertical machining center. there would be no point in turning this on a lathe.

My god is this thing sick...
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Old 04-19-2018, 11:19 PM   #479
sky14
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Your my hero !!
Keep going
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Old 04-20-2018, 03:05 PM   #480
remski
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We all need all the motivation we can get....

Just keep chipping away, bit by bit.
Every 1hr spent puts you closer to the finish line.

On a ****ty day.. ask yourself ....

How badly do I want to drive this thing?

Quote:
Originally Posted by sky14 View Post
Your my hero !!
Keep going
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Old 04-23-2018, 12:54 PM   #481
remski
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So....

Just going to leave it there for now...

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Old 04-24-2018, 10:37 AM   #482
2002Dubx
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Old 04-29-2018, 09:51 PM   #483
remski
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So.. I've been spending days with not much to show..
Chased few electrical issues that are now fixed.


Spent about a day installing this beauty...
Between being a GD exhaust and the 2 rotational axis on the turbo..
What a pita to dial the downpipe in..





Alternator issue is now fixed and its charging now !!!.
Had an issue with the ECU where I couldnt control the fuel..
That is fixed as well. Idles decent at around 14.7 AFR.

Turbo piping is now complete.
Kind of tight but should be ok.





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Old 04-30-2018, 09:16 AM   #484
2002Dubx
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Truly amazing!
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Old 05-01-2018, 04:26 AM   #485
bigBADbenny
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So good!
Can you recommend any resources that detail your loom building process, please?
I learnt plentifully from your build and thirst for moar eg:
https://www.rbracing-rsr.com/wiring_ecu.html
...

Last edited by bigBADbenny; 05-01-2018 at 04:41 AM.
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Old 05-01-2018, 08:39 AM   #486
remski
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Well.. I've read that page as well.
I looked at tons of harness pics to see how they are done.
Vids on youtube how to install connectors.

Engine harness was the easier of the two. (vs the rest of the wiring)
Raychem 25 if you will use that is expensive and you will use more than you think.
Prowire was my source for lots of things.

It all depends whats your direction and what you building.
Tools.. some are expensive as well for one time build..

All for all it comes down to a budget. I've went over mine 4-5x easy.

Anyhow.. ask away.


Quote:
Originally Posted by bigBADbenny View Post
So good!
Can you recommend any resources that detail your loom building process, please?
I learnt plentifully from your build and thirst for moar eg:
https://www.rbracing-rsr.com/wiring_ecu.html
...
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Old 05-01-2018, 01:33 PM   #487
Smurftastic
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You know, I never saw the process of making the milspec adapters until I opened this thread... tedious process indeed, but not impossible for the determined.
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Old 05-01-2018, 01:44 PM   #488
WRX8XB
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Prowire is awesome to work with, very knowledgeable and able to ship out quickly. Highly recommend.
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Old 05-01-2018, 02:20 PM   #489
remski
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Its not really that hard. Most of my "braids" were completed as I went along.
Tefzel wire is really easy to braid.
Use 16 or 32 spec.

I made a mistake and got too much of 12,14 gauge...

What you will be using is (depending on fw connectors) 20 or 22 awg.
My connector uses 22 and thats adequate for our ignition coil and injector amp draw. Door windows got 16awg, then again.. you have take into the account if you are going to use relays/fuses or some kind of pdm. (there are few out there)

Pdm or no Pdm .. as the Motec 20A use 2 pins.
You can stuff a 16AWG in there. Thats what I used for both pumps.
Stocker(feed) uses 1 wire, the 044 uses 2 wires.

I could share my xls that I made, has cluster pinout, Amp draw, fw pinout.

For wire and some boots I used:
https://www.arrow.com

Boots and junctions will add up really quick. Choose the amount of junction wisely. You could also just use bigger heat shrink with epoxy.

Hpacademy now has a wiring course.
I would have taken it if I knew...
$99 most likely will save you tons of research time.
https://www.hpacademy.com/courses/wiring-fundamentals/

Connectors.. Deutsch AS are pricey.
Soriau are a bit cheaper. I got most of my AS off ebay.
Basically hunting before I even started making the harness.

Tools.
If you chose mil spec connectors it would be wise to get a mil spec crimping tool.
I have DMC AF8 but if i was to do it over I'd go with HDT-48-00.
No dies and much more versatile tool.

Yeah.. one could write quite a few pages about the process.
And this is my first harness.


Quote:
Originally Posted by Smurftastic View Post
You know, I never saw the process of making the milspec adapters until I opened this thread... tedious process indeed, but not impossible for the determined.
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Old 05-01-2018, 02:23 PM   #490
remski
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They have an ebay account so some of the stuff is cheaper/free shipping.
They dont offer all of their stock on ebay though.
But yes.. overall they are awesome.

Also used racespeconline once or twice..

https://racespeconline.com



Quote:
Originally Posted by WRX8XB View Post
Prowire is awesome to work with, very knowledgeable and able to ship out quickly. Highly recommend.
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Old 05-03-2018, 11:45 PM   #491
remski
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Here is more progress..

Before:


After:


Brake lines were completed and the system was bled.

Now.. took it for a first drive..

I am reconsidering power steering ...
I've driven cars with no power steering but this is undriveable.
I couldnt make a U-turn !!!
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Old 05-04-2018, 11:46 AM   #492
WRX8XB
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I wanted to warn you about the PS system, it's bad without it. I don't care how strong you are, our setup is designed to have a PS system.

Some people have gotten the Electronic PS pumps to work in the past.
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Old 05-04-2018, 02:12 PM   #493
dWRXa13
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Start em young!
Quote:
Originally Posted by remski View Post
After 1 year, lots of unpleasant calls and a credit card to pay off.

This arrived.

A destroked 2.34, benson sleeved and bored out to 2.5







Had to be inspected on the spot.



With no room in the garage it took the main spot in the living room.



New 2.5 RS intake manifold was purchased and given a shave.



Test fitted with 8mm Grimmspeed Phenolic spacers.

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Old 05-04-2018, 02:13 PM   #494
dWRXa13
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Because race car
Quote:
Originally Posted by remski View Post
Update: Sep.07.2014
Finally some movement.

After a month of waiting and some struggles with shipping company...
This arrived.




Unpacking the goodies.


T45 FIA Certified straight from UK.


Mounting plates.


Dash Bar test fit.


Main hoop tests.


Gave up testing when all of the bars fell apart.


Now trying to find a decent welder that will TIG-it.
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Old 05-04-2018, 02:58 PM   #495
remski
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I am thinking how to relocate the power steering pump where the AC used to be.
Thats looks like the only place it would work.



Quote:
Originally Posted by WRX8XB View Post
I wanted to warn you about the PS system, it's bad without it. I don't care how strong you are, our setup is designed to have a PS system.

Some people have gotten the Electronic PS pumps to work in the past.
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Old 05-04-2018, 03:36 PM   #496
Zombie Panda
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Quote:
Originally Posted by remski View Post
I am thinking how to relocate the power steering pump where the AC used to be.

Thats looks like the only place it would work.


Electric power steering. Steering shaft mounted. Would require a little fabrication for mounting plus some creative wiring... but would completely eliminate the hydraulic pump and lines. Youíd still need to create a bypass for the rack like the Honda kids do but all of this is well within your skill set based on what Iíve seen you accomplish so far.
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Old 05-04-2018, 03:49 PM   #497
remski
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Since I have space on the driver's side of the engine I am thinking about moving the pump there... (where AC used to sit)
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Old 05-04-2018, 08:06 PM   #498
bigBADbenny
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MY07 Lib GTB 6MT Wag
OBP

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Love it!
So thatís 2.5L on a 75mm crank? Awesome.

Opel/Holden Astra elec ps pump is an option, can be mounted in the trunk...

Thanks for the mil/race spec harness info, exceeding expectations: as always!
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Old 05-09-2018, 09:13 PM   #499
remski
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Used power steering pump is on order..


On another note found a little scorpion thingy.



Roof has been glued in and riveted.



Up next was the windshield.
Mobile installs are really nice.




A new hole has been punched in the firewall to accommodate gauge and wideband wiring.



Besides that, Speed and knock sensors have been connected to the ECU.
Tach output now works as well.
Lets not forget about check engine light.
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Old 05-15-2018, 01:50 PM   #500
remski
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Finally the back place is on !!!



Started playing with paint correction.
Wet-sanded and polished...
I think this will work just fine.




The dash is in as well.



Few issues ironed out .. like my master disconnect had to be rewired, since it did not shut off the car while running.

Another issue that crept up was the coolant temp.
Originally the car had a 3 wire sensor. I've changed it to 2 wire..
The ecu reads the temp but the cluster gauge operates on 12V and it doesnt work.
The 3 wire sensor has 2 thermistors. 1 for Ecu and 1 for cluster gauge.
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