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> Rebuiding Inside-out
bkrantz
post Aug 14 2020, 08:35 PM
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Starting with the yellow wire, I carefully removed the crimp connectors.


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bkrantz
post Aug 14 2020, 08:36 PM
Post #1102


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Then weave the wire cores together.


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bkrantz
post Aug 14 2020, 08:37 PM
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Then solder.


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bkrantz
post Aug 14 2020, 08:39 PM
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I did the same for the red lead (and I managed to remember the heat shrink tubing for both).


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bkrantz
post Aug 14 2020, 08:40 PM
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Slide the tubing into place. This is marine grade with internal adhesive.


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bkrantz
post Aug 14 2020, 08:41 PM
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Then hit it with the heat gun.


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bkrantz
post Aug 14 2020, 08:42 PM
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I did the same repair on two leads to the light switch.


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bkrantz
post Aug 14 2020, 08:44 PM
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Today was another milestone. I went to the powder coat shop to fetch the first batch of refinished components. I used Evolution Powdercoating in Durango--highly recommended.


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bkrantz
post Aug 14 2020, 08:46 PM
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Checking out all the parts. I remember everything except the heat exchanger ductwork, which got high temp powder coat.


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bkrantz
post Aug 14 2020, 08:47 PM
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Here's the engine sheet metal, air filter housing, and intake plenum.


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bkrantz
post Aug 14 2020, 08:49 PM
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Of course, powder coat, like paint, reveals any flaws in the metal. The section where I welded cracks is not perfect, but will work.


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bkrantz
post Aug 14 2020, 08:50 PM
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Here's the front suspension, with a slightly lumpy steering cover.


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bkrantz
post Aug 14 2020, 08:53 PM
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And the rear suspension. The biggest miscommunication led to getting the inside of the rear wheel bearing cavity powder coated. I will need to remove this before installing the bearings. The shop did a great job of protecting other areas and all threaded holes.


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bkrantz
post Aug 15 2020, 08:13 PM
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I got my supply of colored wire (4RCustomsWire) and metric connectors (Bel Metric).


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bkrantz
post Aug 15 2020, 08:14 PM
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Also a first time to use my fancy crimp tool, with correct jaws fitted.


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bkrantz
post Aug 15 2020, 08:15 PM
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Here's a test crimp, with a typical spade connector. Looks very correct.


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bkrantz
post Aug 15 2020, 08:18 PM
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And here's a typical repair: replacing about 6 inches of mangled original wire with the new piece soldered onto the remaining lead, covered with heat shrink tubing, a new connector, and heat shrink on that, too.


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bkrantz
post Aug 15 2020, 08:19 PM
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For another repair, I replaced a complete section of wire, from one connector to the next. The crimp tool handles double wire without a problem. (The new wire color match is not perfect, tan vs. brown).


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bkrantz
post Aug 15 2020, 08:20 PM
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New ring terminals for the battery tie-in, crimped and soldered.


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bkrantz
post Aug 15 2020, 08:21 PM
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Another repair for a mangled lead--I even matched the green wire with white stripe (sort of).


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