New Interior

[Eh_nigma]

Thanks!

Okay, tonight I managed to finish installing the Oil Pressure Sending Unit to where the old OPS was located - what a piece of junk... I WILL be posting a "how to" as it was an absolute pain in the ass - having to remove the starter was one thing, but the screwed up thread that GM used for the sensor ruined most of the day.

None the less, once the instrument is completely hooked up and working - key word, working - and I'm sure that this procedure is the right way of doing it, I'll post pics.

As well, I have high hopes for getting the water temp gauge installed tomorrow as well.

Things were going smooth until there was a clutch issue with another vehicle - I'll post the video tomorrow of the clutch - what's left of it...

Futher more, the final piece to the bottom of the roll cage is bent, cut, and shaved to fit...

The "lever" master power switch is also well under way. The mounting brakets have been cut and drilled, as well as the plate... it's just a matter of getting the lever to work - a few versions were attempted, and I'm hooked on one for sure now... it's a bit of a pain, as it's also incorporating the ignition, acc switches as well, and the wiring for all the gauges going up top, and as well as the selector switch to select whether the Volt meter gauge is displaying the main battery, or the accessories battery for the sound system.

So, yeah, a bit on the go... BUT, so far so good... another long day tomorrow, but, none the less, it's being done out of enjoyment. Thanks again for the support, and patience with this project.

[Eh_nigma]

The "How-To" on the Oil Pressure Sending Unit is up...

None the less, that's all wrapped up, I'm just here taking a break, before the Water Temp Gauge, once those are both done, then, yeah... I'll be back.

[Eh_nigma]

Alrighty, managed to get all the interior wiring connected for the oil pressure and water temp gauges. They are working, however I have to still run the wiring through the fire wall... so the TEAL colour wire you see is only temporary.

Well, lets start with the thing that slowed me down... emergency clutch replacement for a buddy - excuse the blurry beginning...

Paper thin clutch - http://s171.photobucket.com/albums/u...t=MOV00755.flv



Now back to the Alero...

The Water Temp gauge was pretty easy actually. Just tapped the upper coolant line and put a coupling overtop to stop any leaks. Although, I'm thinking I might redo this at a later date.

Sensor on hose - http://i171.photobucket.com/albums/u...a/DSC00759.jpg

The one thing that is concerning me, is Haynes says that the normal operating temp for the 2.2L is 180 Deg. F. I'm running at a steady 142.

The Oil Pressure Gauge is also done. The OPSU was a pain in the ass to install, as the tight spacing and having to remove the starter... not to mention the thread issue with that item... there's a picture of the bolt I ended up tapping and using with a new thread...

Adaptor Bolt (on left with teflon tape) - http://i171.photobucket.com/albums/u...a/DSC00738.jpg
Starter Removed - http://i171.photobucket.com/albums/u...stucha/H23.jpg
OPSU Installed - http://i171.photobucket.com/albums/u...a/DSC00739.jpg
Tight Space - http://i171.photobucket.com/albums/u...a/DSC00740.jpg

The Gauges themselves were interesting in the install... but started at about 11 last night, and things were going good, ended up finishing at 5AM though... takes a while doing everything alone...

Blue Face - http://i171.photobucket.com/albums/u...a/DSC00762.jpg

After work today I'm going to go in and clean up the wiring - the input lines for both gauges still need to be done, but that'll be done once I fish the wires through a point in the fire wall.

All works well, Oil Pressure at 1000 RPM (normal between 50-80 PSI) is steady at about 65 PSI, but that coolent temp is bothering me...

More later tonight.

[Eh_nigma]

forgot to mention, the "mounting" for the instruments is only temporary, waiting for one more than I'll fabricate a mount for them... there will also be a switch between the Voltmeter and the Oil Pressure Gauge, hence the space...

[strtrydr]

cool man ... sounds like ya got some more good ideas ... looking forward to see more

and once again awesome work man

[Eh_nigma]

Thanks. Just this work schedule keeps getting in the bloody way of everything. Why, oh why, couldn't I be payed without having to go to work?

Just got off the phone with a buddy of mine... the clutch works, and as a thank you, he's getting me the Tach. from the same series as the other gauges... hopefully it'll work... though the Alero doesn't red line at 9,000, and keep going till 11,000... but, meh...

[antichrysler]

Originally Posted by Eh_nigma

though the Alero doesn't red line at 9,000, and keep going till 11,000... but, meh...

Not with that attitude

[Eh_nigma]

Works a pain in the ass as of late - late nights, and still dealing with the clutch issue on the other car... not as easy as throwing in a competition clutch (the whole thing slid in great, done by the book, with no complications at all - except the clutch wont disengage now... needless to say there were a LOT of colourful words being thrown out there last night... last night wasn't a good one).

None the less, I tried calming down by working a bit more on the 'ho. What did I find... first, I'll be redoing the sensor location on the rad hose. I'm going to get a new pipe, and make the location at the bottom of the hose where it comes into the rad from the engine, mounting the sensor on the bottom side. I picked up another gauge just the same, and will try the new sensor. If it's still reading 142, than it's reading 142, not going to worry any more about it.

The Tach is great, works like a charm, except now it's a matter of placement, and finding a speedo that matches. If it doesn't match, than it'll just be the stock speedo with a roundel and tinted plastic put overtop to match as close as possible.

13 days until my trip back to Alberta, so I need to start kicking myself in the ass and getting it ready to head home for 3 weeks, where I do hope that the interior may just get finished finally...

As well, I've started going through the Haynes manual and rewriting a new version specific to my car. Too much has been done to try and remember it, so wiring schematics, number values, part numbers, locations, instructions on removal/inspeciton/installation of new parts need to be put down on paper. As well, it'll allow me to thin it out so that it is, like I said, specific to this car, this engine, this setup.

What more? Hmmmm... meh, that's about it. Time to go back to work.

[cherrington17]

hahaha... rewriting a haynes manual. nigma, you are one crazy canuck!

keep it up!

[Eh_nigma]

Originally Posted by cherrington17

hahaha... rewriting a haynes manual. nigma, you are one crazy canuck!

keep it up!

Well it's missing key things - Ie., Troubleshooting, with the engine turning over but not starting, lists half a million things, but doesn't list the Security Reset that Joel mentioned when I had that problem. New values (Ie., Oil Pressure, not just normal operating ranges at 1000RPM, but acceptable ranges at all RPM's/Engine Loads). DexCool replaced with Antifreeze Green, and the new thermostat. NOTHING being listed about the Oil Pressure Sending Unit (stock), or the fact that it goes off at only 5 PSI, which by that point, you're screwed anyway, and that if there is a break in that circuit anywhere or the sensor is junk, well, that little light wont go off anyway. Things like that began to bug me, important things. Not to mention it lists about a billion times that Gasoline is flammable. Really? I thought I put it in the gas tank to add weight to the back - sucker keeps emptying on me every 500 klicks, I think it must have a leak somewhere... anyone got bubblegum?


It's a labour of love though... right? If I wasn't enjoying it, I wouldn't be doing it.

[jturkey69]

this whole project is looking awesome...youve written a book and a half, and haven't given up yet!!...keep goin dude!

turkey

[Satsuriku]

rewriting the haynes manual............now thats f*cking awesome!!! hahaha! should rename the book lol

[cherrington17]

^he would.... but no-one can pronouce that name...

[Eh_nigma]

Hey everyone.

Well, as it stands, things as of late have been pretty bloody busy. However, looking at things from a whole, it's not too much to complain about. Summer leave is just around the corner, and that should offer three solid weeks without distraction.

I'd like to get ALL the wiring and metal work inside the car finished up to the point where I can spray it all inside with primer gray. The dash will not be FG, but covered in leather, along with a few other parts. Unfortunately, I wont be home in time to see the car show in Lethbridge, but that's the way the cookie crumbles sometimes.

Aside from all that, looking at the project as a whole - still looks like it can be finished up in time for next spring. Crossing my fingers though.

[Eh_nigma]

So, yes, on leave, having fun with the car (hint-hint Rob, I'm in Lethbridge)... everything's going good... except for now needing a new fuel tank - don't ask why... HOWEVER, aside from that, ALL the electrical connections through the dash are done - the dash is going to be covered in black leather sometime soon here... the back will be measured up for the sound system placement later t'day or tomorrow... but yeah, just an update to say that it's still coming along.

[Darren8r]

Well I just signed up here and I just finished going through this whole thread and wow, very compulsive project you have going.
Good job. Great thread, very useful and interesting.

[Eh_nigma]

Thank you.

Right now, cutting and welding in the weather we are having really... really... really sucks the big one. None the less... it's goin, and goin good. Minus nearly punching a hole through my fuel tank... that's always fun... close, a little too close, but caught myself before going through and, needing a new tank.


The plan, getting all the metal work, electrical work, and build work (Ie., floors, and cover panels) completed by next Friday - when I have to head back to Shilo. Then once there, all the cosmetic, Ie., FG, Leather work, Carpet work, and sound system installation can be done with ease.

[Eh_nigma]

Just another quick one today... I'm cutting and bending the stainless steel pieces for the floor... this is a rough diagram (not the actual one I'm using, but just something I drew up quickly in paint).

The three panels will also have covers cut into them to gain access to wiring running underneath them, and will run all the way up flush with the forward mounting points for the stock front seats. This should be installed by sunday I hope - not always easy, cutting, and fitting pieces like this...

http://s171.photobucket.com/albums/u...ent=floor2.jpg

[Satsuriku]

you bastard!! and you didnt even call me!! god i could have used your help today!! hahaha

[Eh_nigma]

Well, call me! I'm all for helping