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Hey Evan, I found the wiring harness for the horn, it terminates just inboard of the pass side headlight. I have the harness up to the 2-pin connector for the horn.
Last night was SUPER productive in the shop.
- Front hubs fully rebuilt, installed, torqued to spec. Both sides. Bearing preload was approx 14-15 lbs (on fish scale) of rotation after following service manual procedure.
- Front calipers lubed up and loaded with pads, torqued to spec.
- Horn, located.
- Brake hard lines, completed. Just need to add a couple retainer clips to secure to the frame.
- Spare tire crank freed up and chain lowered. Penned out a concept to rig up a rim holder
- test fit 31” spare in place. Hoping a 33” spare will fit in its place. Didn’t feel like lifting the 33 under there @2am
- Loose part fit the dashboard to determine assembly sequence. I still have some wiring to clean up (and reconnect) before the dash goes in for good.
Called it a night just before 3am.
I don’t think the rims are too flashy. A little concerned about their relative strength when bouncing down a trail compared to a steel rim though. Steel would bend, aluminum will crack (chunks break off)
That looks like Darwins 60.
Evan, can you take a picture for me of where the horn bolts to the front bulkhead, and which way the wiring runs towards the firewall? I don’t even know where to begin looking for it on Redee.
Made two ebay purchases today.
1: turn signal bulb holder to fit into my new combo housings. $8 total for a pair. Hopefully they arrive prior to April 31st quote.
2: 0.79mm diameter pushrod cable and support tube to replace the broken cables for the HVAC air mixer and flow control valve. $14.
I’ll just buy a horn locally, and try to find where the original wiring terminates.
I made it out to the shop yesterday, twice actually. before work (4am-7am) I was mainly tidying up workbenches, and shuffling of parts totes to isolate between MUST DO, and will do eventually. After everybody was asleep (9pm-12am) I got a couple items knocked off the list which somehow keeps getting longer.
Anyways, I made a quick block-off plate for the clutch master cylinder hole one the firewall. Nothing fancy but it works. Kept the momentum going by plugging more holes in the firewall and floor with grommets/plugs from a cheap princess auto kit.
Next up, I made a rearview mirrow adapter plate to allow a Jaguar mirror (free parts from Dad’s part hoardings) to hang in place of the yucky pee-filled OEM unit. After sandblasting all the pee-rust off the dome light plate, I cut out a filler plate from a piece of aluminum I had kickin’ around fromy old golf cart. I drilled and tapped the plate for the Jag hanger, and attached it to the roof with some “free” metric hardware. $0 spent, and one big step closer to Road Legal.
Next up, started to continue legalling-up by reinstalling Side Clearance Lights and a horn. Once again I was digging through parts bins and came up with almost everything…..except the horn is really dead, not even a peep out of it. Easily replaceable.
For the side clearance lights, I started putting in my ebay housings, but I am missing about 6” of the wiring circuit. I must buy (prolly used) two of the female 2-pin connector which has the bulb holder on it. See pic below.
I found the correct connector in a parts bin from 2011, but the bulb holder was cut off it.
Once I get a new-ish bulb holder, I can plug in my ebay 2-in-1 clearance light / turn signal housings.
Perhaps tonight I’ll feel like getting greasy, and finish installing the front hubs and brakes.
Stupid question alert! On which parts SHOULD I smear disk brake lubricant in the front brakes? Just the pins which hold in the pads? On the backing plates of pads too? Honestly, for the first 25-years of my life I neglected (disk brake) lube. Now with age, I’m getting adventerous. But am I using it correctly?
Got it up on the calendar!!
Hoping birthday celebrations don’t interfere like last year. Oldest daughter turns 5 on the 3rd. Father-in-law has a bday on the 7th. Fingers crossed for Saturday festivities.
My sister-in-law is in need of a first car, my wife and I are pushing to get her into my wifes 5-spd Focus for two good reasons. Firstas you said, it FORCES you to pay attention and my sis/law NEEDS that. Secondly, Sam wants back into a Caravan, and her super clean low-mileage Focus has no resale value. May as well get ripped off by a family member, as opposed to a dealership or kijiji person. The sale would have to be accompanied by driving lessons. I’ve taught 4-ppl already, and Focus practically drives itself. Hoping it pans out.
If you ever build ANOTHER rear bumper, lemme know what you want for the current one. Tempted to drop cash on the Marlin Crawler rear, but no tire/fuel carrier. Or drop cash on welder, bender, consummables, ppe, etc and build something.
Adjust the rear shoe to drum clearance again, Crank up the rear pressure, and try bleeding the rear drums again. Start “fresh” in one go.
That’s awesome wifey wants to learn standard. I taught Sam to drive in 4Runneree. Stuck it in Low range, hubs unlocked, and worked through the motions for a few km of back roads. A month later she bought a 5-spd Chevy Aveo from her future brother-in-law and continued on to master the skills on her own.
That front end dive means you must be getting tons of bite on the calipers. Can you lock up the 35s yet?
I really dig your rear bumper, clean fit and effective.
@Toy-Yota I sure hope spring is coming, and that Shelburne gets the memo. I’m tired of shovelling this heavy white shit. 5cm of frozen BS landed overnight.
Home from a week in Cuba (not my idea, but getting a tan in March is never a bad thing), so it’s time to hammer down and finish Stage 1 – Road Prep. I picked up my spring scale to verify bearing pre-load the day before we left, so hopefully I have all the parts and tools I need to button up the front axle.
Sad to see toys go, but a Z1000 is mass produced, vs a RatRod which is pure pleasure! Suuper excited to see what joins the fleet next.
What do you have in mind? Got a decade settled on at least?
I put together a bracket off an existing M8 nut on the firewall for the Prop valve. Original mounted to the rear frame rail, but lucky me I found a spot I liked and can easily reach under the hood, just a bit inboard of the hydraulic booster
Tonight I ran more hardlines, pretty much consumed my night. I only have one short stretch, in a dead straight line to do tomorrow. Ran out of line for tonight.
I also freed up the idle speed adjustor screw that was too stuck to adjust in the summer. I’ve been giving it a spray of PB Blaster once in a while since September, I guess tonight was my lucky night.
Also found troubles with the throttle cable / kick-down plate, it is rotating on application of Wide Open Throttle. When it rotates, the throttle cable gets a bit of slack in it, and isnt taut enough to hit WOT a second time. So that won’t do. Still pondering an anti-rotation solution.
To the parts store tomorrow…1 brake line, 1 big jug of DOT3, 1 air filter for chev. Still waiting patiently for my fishing scale to arrive in-store.
Another successful day in the shop yesterday, really feels like I’m picking up momentum, as my “Due Date” arrives.
I unboxed my new gas tank, and only had to trim a small flange off to get it to fit. Pretty nerve wracking taking a cutoff wheel to a brand new tank, but I measured 378 times prior, and the cut looked decent afterwards. Fits like a charm now.
I pulled all old hard and flex lines for fuel and brakes. I mounted, bent and flared hard lines for the front brakes. The only outstanding hard lines to replace are between the master cylinder and Manual proportioning valve on the rear circuit, and the hard line which runs the length of the frame rail to the rear flex hose (or where LSPV used to be).
I replaced all the rubber fuel lines under the hood, and have a couple short runs from the tank to the Passenger side fender to run hard lines.
I still have to mount the manual prop valve under the hood, hope to do a better job fabricating the bracket than I did the fuel tank retainer 😉
@Slick_Yota what non-shop projects are occupying your free time this winter? Gotta put some hours on that Mastercraft mig welder for me, let me know how it performs. My Mastercraft sandblasting cabinet is working well, just way more dusty externally than I was hoping. Cone spring time I’ll likely relocate it outdoors before I use it, won’t have to concern myself so much with dust control.
Yesterday in the shop I tore apart the passenger side front wheel hub, removed the rotor, trimmed the dust shield and put everything through the parts washer. Those friggen cone washers are always the worst part of a hub teardown in my opinion. Progress has halted while everything drips dry of varsol, and the “fish spribg scale” arrives @ HomeHardware so I can set the bearing drag preload properly (for the first time in my life). I also gotta grab brake line retainer clips locally so I can finish installing brake hard lines.
No pictures to upload today. Phone died from the cold in the shop.
Made some progress today with my buddy James providing some assistance while Sam and the girls were out at the Science Centre.
James swapped tires over on his Mazda before he trades it in next week. Once he was setup with proper tools, I started on Redee.
Today I bent up and flared the hardline to FINISH up the brakes on the rear axle. I noticed today that I’m missing the “spring clips” which retain the flex lines to the mounts, so I’ll try to pick some up locally tomorrow.
After that, I moved to the front axle and began reassembly of the drivers side brakes and hub. I took a slice off the dust shield, and reinstalled it with the new inner wheel seal with a smear of grease in the lip. Repacked the inner and outer wheel bearing, replaced inner hub seal, and tried to set the bearing pre-load without a spring scale. I’ll buy a fishing scale to verify my preset before I snug everything down for good.
Lastly, for good meaure I temp set the hub, threw on a 33” tire and made sure the rims didnt interfere with the new bigger brakes. As expected, all fits well. So my wheel/tire dilemma is settled. Replace dry rotten 33×12.5×15 Geolander A/T, with some freah 33×12.5×15 Duratracs. Now to wait for sale pricing.
Another successful day in the shop.
Mr Fedex dropped off my wheel seals, brake assembly may resume once again.
On Friday & Monday night I made great strides in assembling…*ahem* <b>ASSEMBLING</b> most of the inner dash. I got my new firewall nvh blanket put in, ran and secured tbe wiring harmess, installed the hvac box and all the ducting runs and control cables, the throttle and brake pedal assemblies, dash crossbar and steering column. I also identified <i>most</i> of the wiring connections, and a few mystery wires dangling.
I still need to re-crimp some broken butt connectors, and run new wires for my very old (but free) headunit and speakers.
Lunch is over, more typing later.
