Stirlsilver's Disco Ute Project

Yes im still watching your progress :cool:

More foam fun! I kept the whole thing simpler this time - Balsa wood, superglue, carboard and masking tape.
https://www.aulro.com/afvb/images/im...013/07/530.jpg

https://www.aulro.com/afvb/images/im...013/07/531.jpg


Waiting for the foam to cure.
https://www.aulro.com/afvb/images/im...013/07/532.jpg

https://www.aulro.com/afvb/images/im...013/07/533.jpg

https://www.aulro.com/afvb/images/im...013/07/534.jpg

And the results. Who would have thought that Polyurethane foam sticks to cardboard making it a PITA to remove?

https://www.aulro.com/afvb/images/im...013/07/535.jpg

https://www.aulro.com/afvb/images/im...013/07/536.jpg

https://www.aulro.com/afvb/images/im...013/07/537.jpg

https://www.aulro.com/afvb/images/im...013/07/538.jpg

Looking good...I love getting your updates..each time you do something on the car it always looks like you get so far

I wanted a bit of a change of scenery today. This is what 90% of a 1996 discovery loom looks like:
https://www.aulro.com/afvb/images/im...013/07/478.jpg

It did involve some surgery to get it all out:
https://www.aulro.com/afvb/images/im...013/07/479.jpg

And I started stripping it all apart. I didn't get through all of it. Bottom line is I have loads of wire now. More than enough for what I need:
https://www.aulro.com/afvb/images/im...013/07/480.jpg

Now i'm off to pack and head off to Vietnam tonight and Korea later in the week. I'll be back by friday so I should be able to get some more work done that weekend.

Right, I'm back from my quick dash through Vietnam and South Korea. So today I headed in to the workshop to have a bit of a play.

Firstly, I had to finish up what I started - Stripping down the looms. I don't think i'm going to be running out of cable any time soon!:

https://www.aulro.com/afvb/images/im...013/07/262.jpg

https://www.aulro.com/afvb/images/im...013/07/263.jpg

Also the right hand side rear quarter has been mounted and welded in place:

https://www.aulro.com/afvb/images/im...013/07/264.jpg

Tomorrow I should be making a start on giving the right hand side the foam treatment.

oh my god you are a madman hahaha im going to have nightmares about all those wires!!! haha! impressive! and its looking awesome!!!!!!

I thought I was the only one cheap enough (Scott enough) to use cable from old wiring looms

Love it - my bumblebee's spots (front, top, rear), rear air con, radio, air horn, headlights, relays, and various other bits were all wired using old wiring loom

Also used the relays - watching the progress

If you think I'm crazy stripping the loom down... Just see what I did below...

Anyway, update in the workshop is looking good. Much neater in the prep of the other side:
https://www.aulro.com/afvb/images/im...2013/07/41.jpg

https://www.aulro.com/afvb/images/im...2013/07/42.jpg

https://www.aulro.com/afvb/images/im...2013/07/43.jpg

Also, some more go-fast bits arrived. The Megasquirt ECU is here, some breakout connectors during the testing phase, the Peak & Hold Board (which i'm a bit irritated is in pieces needing me to solder considering how much they cost!!) and a cam synchronizer from a Ford that I will machine and fit onto the bottom half of the Rover distributor assembly for the cam position signal.
https://www.aulro.com/afvb/images/im...2013/07/44.jpg

https://www.aulro.com/afvb/images/im...2013/07/45.jpg

Just in case you were wondering. This is what a COLOSSAL waste of time looks like. I tried to do a 3D model of the turbo using photogrammetry. Too many points. Junking it and I'll try again later... After I get hold of some acetone to wipe the graffiti off the turbo.
https://www.aulro.com/afvb/images/im...2013/07/46.jpg

https://www.aulro.com/afvb/images/im...2013/07/47.jpg
Tomorrow off to Indonesia again for 24 hours. Back on Thrusday but there won't be any play time in the workshop this weekend unfortunately.

I take it that means you are building your own wiring loom for the ECU!

Well at least you will know how it works and how to repair it - do you have a good supply of anti frustration pills?

The cards with the temp wiring points are a great idea - we had to play with our wiring loom for the Haltec to fault find and it was a pain to test back to the plug and then into the ECU.

Very handy design.
Looking good.

I headed in to the workshop today with the objective of getting all the foam work finished. And it was achieved :)

https://www.aulro.com/afvb/images/im...13/08/1444.jpg

https://www.aulro.com/afvb/images/im...13/08/1445.jpg

Next step, shaping the foam and preparing for fibreglass.