Now comes the easy part with everything painted. We put the rolling chassis on the trailer and went off to the body shop and it was lifted on to the chassis and bolted down. Then the trip back home. We're getting excited!
At this point we had the rad and fans in, hoses and AC lines. Next came the inner fenders and front rad shell and grill. Everything is fitting well.
We then hung the doors and trunk lid. All that preassembly is paying off now. No "diddling around" - just bolt it in.
The dash gets assembled and wired. It's coming together as planed - just a few touches to add like radio and AC controls.
We wired the dash with weather pac conectors to make assembly easy and also in the event we had to take the dash out for servicing.
This is the remote assembly box in the trunk. It's simple and cheap to do. Essentially, a simple wooden box housing the relays that operate the power windows and power trunk .The remote unit can run up to 10 amps on its own but anything higher we put on relays . The relay on the top right is for the fuel pump. Next to it on the right will be for interior lights.
A ton of wiring for sure. The computer sits top centre running a multitude of things, such as engine, transmission, fans, AC, and so on. There is a 21 circuit fuse panel and an extra one for the computer. Then 5 more relays for various other interior items . Door pin locks for safety engage when in drive. They also have manual override in case of electrical failure. There are no door handles as entry is remote.
The dashed is now plugged in and the AC head was installed with inter-connectors for easy removal. The TV/DVD/MP3/MP4/rear infa-red camera is also installed. It also has SD card input and USB and I-Pod inputs.
Aboce, you can see up top the wiper assembly ( the motor is in the rear compartment).
A sub-dash panel will house the 3 AC ducts and power window switches. There are approximatley 100 wires to run the engine and transmission and as many (or more) to run everything else. There will also be an outside temp and direction unit which will sit up top in the wiper cover assembly. Next we will show you how to cut the glass.