working on wiring today, for the rear of the body. I am adding dedicated grounds, running all new wires for lights and sending units, and adding wiring for rear facing LED flood lights. But, in order to get the old wiring out, had to drop the fuel tank. I decided to install the new sending unit for the VDO fuel gauge while I had it out. Well don't you know that my aftermarket sending unit doesn't have the pickup tube like the factory one. So... time for some fabrication and fitting to make it work. I pulled the factory sender out and broke it off of the pickup tube. It was not working anyway, so no loss. I then disassembled the VDO sender. Only 2 things I had to do was to open the hole in the factory sender to .395 to accept the new sender, and add a new post for ground reference. Hardest part was getting the new float and all back through the hole. Had to reposition the float to the correct place once I got it in. Below is a pic of the altered sending unit. and I did make sure to check the ohms BEFORE I reinstalled it in the tank, and also after I put it in the tank. Nothing like an unwanted ground to mess up your day.
More work on the rear wiring tonight. Layout of the rear harness, new TXL wire, circuit printed, with integral grounds. Hope to eliminate any "wiring problems" by replacing everything . Here is a picture of the printing on the wire.
Last edited by auskier; 09-01-2013 at 10:24 PM..
Made a fair bit of progress today, it was sunny so I didn't have to work only in the garage. Started out installing the rear lighting harness I made last night. Fit was pretty accurate, and size wise it was as small as the factory one, even with my added circuits for dome light, rear work lights, and dedicated grounds. I managed to hide the 2 harness covers for by the driver side roll bar. I cleaned the garage up so well it took me 30 minutes to find them, but they finally turned up. After that, I got the heater box, fresh air box, both rebuilt over the summer thanks to some great threads here, defrost duct and hose installed. E-brake pedal was put in place and re-attached, as well as I got the tail lights connected and bolted back down tight. Last pic is of my modified fuel sender reinstalled in the tank. I ran a dedicated ground for it as well, and put in a weatherpack connector for easy tank removal and installation.
Spare tire carrier is up next as soon as I find the correct bolts for it. Is anyone using a plastic washer in between the carrier brackets and tubing? Or some bushings? I had my carrier powdercoated and don't want to mar the finish. Any ideas on where to get some washers and the shoulder bolts are appreciated.
It's been a quiet week, not a lot has gotten done. I did manage to install the tire carrier and sand blasted my extra support pieces from Keith's design. I also found a pair of 7/16" stainless hex bolts to replace the rusted pivot bolts for the tire carrier. a 3" hex bolt has the perfect length of unthreaded shoulder to replace the factory bolts. Just trim to length. After that I got the roll bar set back in place and started bolting it down. I have to say I really like the powdercoated finish!