More Chassis Work

I’ve had a bit of time this week to work on the car, but not a ton. Its been a frazzling week at work and I haven’t had energy the last two days to do a lot when I got home. I’m still plugging away to get to the point where I can install the body for good.

In that vein, I got some work done on the wiring as well as the transmission tunnel and some other sheet metal.

The chassis wiring has been mostly finished for a while, but the actual tail ends of the harness — the tail light pigtails, license place light pigtails and the front wiring harness — weren’t necessarily bundled up in loom and attached to the car.

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On the driver’s side of the front of the car, I had to bundle up the harness wiring for the driver’s side lights, the horn and the harness that runs under the radiator to the passenger side. I also mounted the harness for the HID ballasts, but forgot I did it and didn’t get a photo of it.

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The harness that goes under the radiator sticks out on the passenger side. The harness is mounted with clamps in some places, zipties in others.

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On the rear of the car, the passenger pigtail is mounted up to the side of the trunk using a clamp.

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On the driver’s side the same thing was done.

I ran the harness for the trunk light, but haven’t mounted it yet. I also am having problems finding a place to mount the horn, so the horn wiring may need “massaging”.

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The sheet metal that goes around the radiator gets installed once the body is on the car — the body won’t fit with it on before. To make it more easily removable, I used four rivnuts. I’ll use some threadlock and small bolts to hold it to the car. I still have the passenger side one to do, and have to figure out how to mount the bottom piece as well.

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I also got the rest of the rivnuts mounted on the transmission tunnel.

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The two trim pieces are done for the sides of the transmission tunnel. There are a few more pieces I need to fabricate, but its detail parts, not functional ones. The goal right now is to do the minimum I need to get registered. I’ve got all summer to work on detail.

The last thing I did today was start to make a “punch list” on the white board, organized in three lists: stuff to do before putting the body on, stuff to do after the body is on but before the state inspection, and stuff to do after that.

Before The Body

  • Install backup light
  • Install harness shoulder straps
  • Air blower wiring into the dash
  • Close up hole in the driver’s footbox where the bolt for the Wilwood pedal mount is
  • Mount the horn
  • Finish nose sheetmetal mounting
  • Mount license plate light harness
  • Fix a small leak around the zing plug in the radiator
  • Mount O2 sensor harness
  • Mount USB plug in lower dash panel for the ECU
  • Install brake duct boots in the body
  • Figure out what to do with the fuel tank vent
  • Install bulb seal

Before Inspection

  • Install elephant ears
  • Install rear splash panels
  • Install remaining cockpit sheetmetal
  • Install wipers
  • Install windshield
  • Install doors
  • Install mirrors
  • Install hood
  • Install trunk
  • Install latches
  • Install dash
  • Install Russ Thompson turn signals
  • Install steering wheel
  • Finish the transmission tunnel
  • Run power to the cigarette lighter outlet
  • Patch e-brake hole
  • Patch varous cockpit holes
  • Install replacement Digital Guard Dog controller
  • Install gas cap / LeMans cap

Once Registered

  • Heater wiring
  • Seat heater wiring
  • Fabricate heat control panel
  • Install door panels
  • Install carpet
  • Fabricate and install shifter and e-brake trim
  • Install vent ducting
  • Fabricate center console
  • Install defrosters
  • Tune the engine
  • Align the car
  • Install side pipe hangers

These are really long lists, which make me feel a little less certain about getting it done in time. I’m hoping to get through the first list this weekend, and cherry pick off the second list prior to the following weekend. If I get the body on that weekend, I have two weeks to finsh the second list and get the car inspected.

I may find I have to take a couple days off to get the car ready for the Open House, or I’ll need to try to get more help with it from local guys who have done some of these things before on their cars.