Cars


Mini Rebuild

 

Step 50 - Wiring Harness and Jacking Point Fabrication

 

Now that we know she drives, time to turn our attention to the electric system. There are 3 basic phases here:

1. Designing the entire electrical system

2. Obtaining all the necessary components and tools

3. Building the bloody thing

 

Considering I know even less about electricity than I do about restoring old cars I decided to take a much-needed break from the garage and spend some time researching. I read a few books on the topic of vehicle electrical systems as well as a few insightful web pages. All of them proved informative and gave me enough false confidence to proceed with the wiring harness design. Here is the end result:

 

Wiring harness design (JPEG) I used the 2003 Yamaha R1 Haynes manual wiring diagram as a starting point to create the harness in Microsoft Visio. I then removed most items I didn't need and added all the various subsystems and compenents (marked in green) that I did need.

 

Electrical System Layout (JPEG) This diagram shows the rough location of each electical component within the car.

 

I am still calculating the total amperage of each circuit and double-checking my work for mistakes but the basic design is now complete. Complete enough at least to allow me to start ordering parts. I am using a company out of Michigan that specializes in race car wiring harnesses. Most of the parts and tools I will need are on the way. In the meantime I focused on various sub-systems:

 

Mini Rebuild - Step 50

I purchased these nice glass headlights and an HID kit go with them. It took a bit of fiddling and testing to get them working properly. Once I got them working I caught one of the wires on my shoe while walking past, dragging both headlights to the ground, shattering them. I think the HID bulbs are intact. I was too disgusted with myself to check but I will shortly. BTW, I went with HID primarily since the electrical draw is so much lower than conventional incandescent headlights. The R1's alternator has good power output but I wanted to be on the safe side. Combined with HID's excellent light output, this seemed like a good choice.

 

Mini Rebuild - Step 50

I purchased a variety of sizes and colors of Tefzel wiring for the car. I'll be working with this stuff very soon.

 

And while I'm waiting for the remaining electrical components to arrive, I've decided to knock out another area of the car. Every time I've had to jack this car up I've had issues. The floor is just not strong enough to support a hydraulic jack, nor jack stands. I've used wide boards to spread the load out but I've still managed to mangle the floors a bit in places. I decided the best thing to do is to take advantage of the roll cage's strength. My first thought was to weld in dedicated jacking plates at all four corners of the car. While perusing the Internet for further ideas I came across photos of rally cars that were jacked via the rollcage:

 

 

 

This seemed an ideal solution and after a little bit of planning, I ordered a small lightweight jack and a set of stands.

 

 

Mini Rebuild - Step 50

 

Mini Rebuild - Step 50

And here I am installing receptacles to accept the jack stands. I ordered some 1.50" x 0.12" DOM steel tubing to fabricate the jacking points and to tie into the rollcage. I thought it would simplify things to match the size of the existing rollcage and I figured this would be plenty strong enough to support the weight of the car.

 

Mini Rebuild - Step 50

 

Mini Rebuild - Step 50

Here you can see the hole I drilled in the back of the car.

Mini Rebuild - Step 50

 

Mini Rebuild - Step 50

Here I am test fitting the connecting pieces/braces that will tie the jacking point into the cage.

 

Mini Rebuild - Step 50

Please ignore the ugly welds. They didn't turn out nearly as nicely as I wanted but I think they are strong enough for the task at-hand.

 

Mini Rebuild - Step 50

 

Mini Rebuild - Step 50

This is the beginning of the front jacking point. Notice the cardboard template I used to ensure the holes ended up in the same location on both sides of the car.

 

Mini Rebuild - Step 50

And here are the supporting pieces for the front jacking point.

Mini Rebuild - Step 50

I hope to have the jacking system finished up this week.

 

Continue to Rebuild Step 51

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