Wiring pt1

So onto the wiring - a mammoth task given the amount of Saab wiring I had to try and sort out - bearing in mind the Saab had electric everything and its many computers monitored all sorts of things. There was lots of stuff to bin and it took many weeks deciphering wiring diags.

Starting with the Zero Loom, a hole was cut for the fuse box. This had 2 spare fuse holes so I used these for the fan and the fog light. Zero loom does not have in my opinion good enough wiring for the fog and horn, and nothing at all for the fan so I re-used relays and wiring from the Saab to run them.

From Zero 020511

For anyone who doesn't have this, its the connections required for the column and ignition wiring.

pin ford gbs purpose
headlights 15 brown white (thin) ignition
headlights 56 brown black brown black link
headlights 56a brown yellow white orange main beam
headlights 56b brown white orange black dip beam
indicators 30 red brown (thin) constant feed
indicators 49 black red green flasher relay feed
indicators 54 black white (thin) ignition
indicators 49a black white green yellow feed to flasher unit
indicators L black white green red left indicators
indicators R black green black green right indicators
lights 30 red brown (thin) constant feed
lights 31 brown white (thin)
lights 55 empty
lights 56 brown black brown black link add wire to fog light switch
lights 58 grey red side lights
wipers 53 green yellow blue slow speed
wipers 54 black violet white (thin) ignition
wipers 53-2 black green
wipers 53a black violet
wipers 53B red grey red fast speed
wipers 53c black orange washers
wipers B1 brown white
wipers B2 brown yellow
wipers W black yellow
ignition switch black yellow white (thick) ignition
ignition switch red brown (thick) main feed
ignition switch black blue white red starter
ignition switch yellow accessory
red white horn
black earth
grey fuel sender
yellow black brake warning

Tunnel Tops

A little out of sequence in the build, but the tunnel panels were trimmed in vinyl with spray contact adhesive from Halfords and bolted with Rivnuts and dome-head socket bolts

From Zero 020511

Fuel Filter

Found on ebay for 99p! Just an injection filter for an Omega or Astra or something. Aluminium sheet cut to strips to make brackets, Rivnutted onto the pedal box.

From Zero 020511

Accelerator Pedal

The pedal didn't provide enough travel to fully open the throttle butterfly so I welded a piece of 3mm steel onto the pedal and also made a clevis out of 3mm plate and some nifty welding to allow for the rotation of the pedal.

From Zero 050611

Slightly tricky to see but there's the single strip of 3mm metal, roughly 12mm x 40mm with the first 10mm of it welded to one side of the top of the pedal, a 5mm hole in the top of that strip, a clevis which is really just a U-shape made from 3mm strip, all linked together with an M5 cap head and washers to space it out.

Throttle

After another lull in posting, we have some more progress to report!

Throttle cable action - used a bike brake cable, the barrel shaped nipple on the cable fitted into the original Saab throttle linkage. At the other end a cable nipple from ebay was purchased. The threaded adjuster is off an old bike brake lever I had in my stock of bits and pieces I've hoarded in the garage. You never know when things come in handy!

From Zero 020511

The aluminium plate bolted onto existing holes in the throttle body, to provide a cable stop. Shaped with a hacksaw and files, from strips of aluminum and aluminium angle, then low-temp welded/brazed again.

From Zero 020511

Seats

Not much to say, seats & harnesses fitted! Mounted straight onto the steel floorplan, driver's seat on sliding brackets from GBS.

From Zero Dec10

Inlet Manifold

We used a Saab 9000 manifold as it has the inlet on the end rather than the 900's original one that went over the top of the engine and was way too high to even consider using. The issue was that the inlet faced into the bulkhead so we cut off the ends and rewelded the opposite way round. Was tricky to get it all lined up but made an MDF jig to help matters. We used a low temp aluminium brazing kit from ebay (£15) and a plumber's type propane torch - it worked for the manifold cutoff onto the flange but was not powerful enough to heat the mass of metal of the manifold to get the solder to flow properly so we enlisted the help of someone with Oxy-Acetylene, the bodged up the leftover holes with JB Weld. Fingers crossed it works.

From Zero Dec10

Ends cut off.

From Zero Dec10

Rough position it will end up in. Used 70mm OD aluminium pipe to extend mounting position.