Rear fog light re-route wiring

 This one was irritating me...

I am not sure if the wiring route I took was wrong, the wiring had got snagged behind the rear panel or something completely unrelated however the rear fog lamp wiring does not reach the spade connectors in the fog lamp.

Only option was to carefully drill a new hole in the rear panel (being fully conscious there is a fuel tank at behind it) and poke the wire through the new hole. The new position for the hole actually produced more slack in the wiring so re-routing the wire did not ultimately prove to be too difficult and thus dismissed the initial idea the wiring had got snagged when the rear panel went on as it was free and easy to relocate to the new hole...

The fog lamp (as is the reversing lamp) are modified versions having been adjusted at the rear for the angle of the rear panel so they sit vertical to the panel when fitted. You can do this yourself but GBS stock the modified ones done expertly and finish with some trim - job sorted!

Speedo Sensor

 This is fiddly! Fat fingers are not helpful for this.

Its also helpful the handbrake cable is moved out of the way whilst you do this.

the speedo bracket was fitted relatively early doors in the build. If you avid readers will recollect the hole the sensor goes through was elongated to provide for movement up and down relative to where the driveshaft bolt passes the sensor head.

The distance between the driveshaft bolt and the sensor is between 1 and 2mm above the bolt heads so make a trust template to that depth and place it on top of the bolt. Pass the sensor through the bracket and here is the fiddly bit. It is held in place with a nut top and bottom between the bracket... the bottom nut is extremely faffy to get in place without losing it down the drive-train tunnel.

Once the bottom nut is on you can adjust accordingly with the template to guise the sensor to the right depth by turn the top nut accordingly.

Exhaust

Been waiting on a stock of exhausts to come into Kitspares so it was good to receive this new exhaust through the post earlier in the week, together with the exhaust mounting bracket.

Apart from some exhaust paste (thanks Halfords!) before you can fit the exhaust to the manifold you will have to saw two slits into the manifold pipes approx 4cm long. This will enable the manifold to contract when you slide the exhaust onto the end of it.

Once you have the exhaust in position you can mark where the exhaust bracket fits relative to the exhaust outlet, take it all apart and then.... realise you will have to also take out the passenger seat to drill the holes!

Initial pilot holes from underneath then opened out from above. The bracket fits into place with Nyloc nut and bolts. remember to apply the nut from underneath in the unlikely event it comes off the bolt will still remain in holding the bracket on!

Put the passenger seat back in, re-fix the seat belt - what a faff, something else to add to the growing list of "Don't get too far ahead without seeing whats coming down the line to fit" list.

Apply the exhaust paste, push the exhaust onto the manifold and clamp in with the exhaust clamp wiping away any excess paste. Apply the exhaust spring to the bracket, exhaust outlet and hey presto one exhaust fitted.

Looking more like a car now!