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Post by mprmurray on Jun 29, 2019 19:48:46 GMT
Great thread russ. A great help to me as same model donor so fuel lines etc helping to answer many questions and similar stage of the build at present but not sure I will keep up as your making quick progress.
For the coilovers I was planning the same as Stuart had them on the demo car, did you go for adjustable dampers, not sure the extra is worth it as not sure I have the knowledge to mess around with the dampers and only planning road use.
Keep up the build updates. Thanks
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russhowell
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2004 1.8 Euphonic Mk 2.5 Arctic Blue 75,000Miles
Posts: 141
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Post by russhowell on Jun 30, 2019 16:28:56 GMT
Cheers for the Kudos. I did not get the Adjustable Damper model, as I am trying to keep costs down, plus I plan to sell it within weeks of finishing, so I can do another one to keep with all the bells and whistles. However even this one is getting a fair bit of snazzy treatment and alot of careful thought and consideration. Will post bulkhead and initial wiring tomorrow.
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russhowell
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2004 1.8 Euphonic Mk 2.5 Arctic Blue 75,000Miles
Posts: 141
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Post by russhowell on Jul 1, 2019 8:52:59 GMT
Made a template and managed to make the rear bulk head in one piece, which I am really pleased with. Used thin rubber between bulkhead and frame so I didnt have to mess about with TigerPU, incase of future removal.
Installed the hand brake and used a grommet from Trigger, which I first saw in Hammy's build looks quite tidy.
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russhowell
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2004 1.8 Euphonic Mk 2.5 Arctic Blue 75,000Miles
Posts: 141
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Post by russhowell on Jul 1, 2019 9:00:37 GMT
Started the wiring loom over the weekend. Did not fix the cable tray in, incase I needed more holes and indeed i did. SO made a few more entry\exit holes as I do not want any cables going over the top of the frame, and currently looks like i will win. Got a hole to make to the right of the pedals for the wires that go down the right wing.
Plugged everything in to see what would happen after 4 months and to my astonishment, i got activity on the dashboard. Low fuel and battery light. I then turned the key to see if engine would click\turn over and nothing at all.
There is some humming coming from manifold area of engine.
I then noticed the main earth strap from engine not connected. I connected it (badly) to a point. Turned the key and loud pop.
Now no activity at all on dash or anywhere and no humming.
Obviously I have blown something but fuses all look good, although the 60a ignition fuse may look a little black, but I thought it would melt and show clear daylight in the middle. I'll replace and try again and fix all earths properly.
I would appreciate if anyone knows if the humming type noise is normal, such as fuel pump or something, and also if anything else to check once I have all earths done properly as I wasn't expecting a fuse to pop just by connecting an earth strap.
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Post by Stiggy on Jul 1, 2019 9:11:03 GMT
it maybe the IAC (idle air control valve) that is buzzing, or the coil pack. Maybe a relay is buzzing as it is trying to close but can't due to arcing as it maybe found a bad earth path when you tried cranking without the earth strap on engine.
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russhowell
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2004 1.8 Euphonic Mk 2.5 Arctic Blue 75,000Miles
Posts: 141
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Post by russhowell on Jul 1, 2019 9:16:30 GMT
Thank you Stuart. I ready that 99% of probs are due to earths. Will double down to ensure all clean and tight. Replace fuse and try again.
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Post by hammy3601 on Jul 1, 2019 16:33:24 GMT
Just fixed a constant buzzing that was the AICV as Stu says. However if your buzzing stopped after the PING I'd go for the earth/relay scenario Stu already said. AICV sounded like it was coming from the K&N cone but that's dues to resonance and the K&N acting as an amplified speaker mate.
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russhowell
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2004 1.8 Euphonic Mk 2.5 Arctic Blue 75,000Miles
Posts: 141
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Post by russhowell on Jul 2, 2019 7:16:19 GMT
Yes it sounded exactly like it was coming from the K&N cone filter. lol. Will deal with solidly sorting all earths and try again. cheers
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Post by jleigh5 on Jul 2, 2019 7:45:53 GMT
Hi Hammy How did you fix the humming from the AICV? Cheers
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Post by hammy3601 on Jul 3, 2019 8:04:55 GMT
Hi Hammy How did you fix the humming from the AICV? Cheers I got another second hand throttle body complete with ICV for 20 quid and swapped it over mate, 5 minute job. Interestingly Mazda wanted 400 quid for an ICV on its own! :-)
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russhowell
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2004 1.8 Euphonic Mk 2.5 Arctic Blue 75,000Miles
Posts: 141
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Post by russhowell on Jul 3, 2019 9:36:41 GMT
It turns over... woo hoo.
I doubled down yesterday and went to work on all my earth points, with all the info I could glean from the forum. Still wouldn't even light up a light on the dash or make a click anywhere. My multimeter confirmed no fuses had gone, even the 60a ignition fuse that I thought had popped, was still good.
I was just about to pack it in for the night, when I noticed another darn earth. Its the one on the negative battery lead about 12 inches from the battery terminal\end. DOH!
Attached it, and it all burst into life.
I cannot explain why i had activity a few days ago, unless that earth point happened to be touching, but I doubt it. I cannot explain the loud pop either.
So it still stands that over 90% of issues are down to earths.lol. Now on to stripping a bit more wire out...what could possibly go wrong!
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Post by ancsportscars on Jul 4, 2019 7:54:52 GMT
Have you also checked that the PPF has got its own dedicated good earth connection near the diff? A couple of decades of British winters often means they have corroded and broken off - so could easily be missed.
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russhowell
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2004 1.8 Euphonic Mk 2.5 Arctic Blue 75,000Miles
Posts: 141
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Post by russhowell on Jul 4, 2019 12:18:44 GMT
Thank you, yes indeed it had broken off, but i secured another ring connector and it was one of the few earths that was initially good. Anyway, its all totally working now, so more wire to strip out cheers
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russhowell
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2004 1.8 Euphonic Mk 2.5 Arctic Blue 75,000Miles
Posts: 141
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Post by russhowell on Jul 8, 2019 8:08:09 GMT
Had a break from the wiring and fitted the radiator. It all seems to test fit with the bonnet, so hopefully good during final fit.
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russhowell
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2004 1.8 Euphonic Mk 2.5 Arctic Blue 75,000Miles
Posts: 141
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Post by russhowell on Jul 8, 2019 8:09:29 GMT
Thought I would share my removed wiring loom. I have 4.3 Kg or 9.7 lb
Not including all the tape and other wiring covers\sheaths
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