Aux Panel Wiring

I have been faffing with the aux plug wiring for a while.  There are a couple of issues:

-  I was sent a hazard warning light switch for the aux panel when the Ford wiring is designed to use the switch on top of the steering column.  I didn't realise until I had already fitted the switch to the aux panel.

-  I was inspired by Richard Lincoln and want the Savage switches to illuminate with the side lights.

Once I had the plug wiring set up for the hazard lights switch, I set about modifying it to include wiring for the LEDs.  Here's the schematic I ended up with:

It is simple in principle: there is a 5K6 resistor from aux plug pin 1 (side lights) to the +ve terminal on the LED along with gratuitous use of diodes to stop the current flowing back where it shouldn't go.  The diodes are orientated so that current can only flow INTO the LED +ve terminal.  The net result is that the LEDs illuminate dimly with side lights on.  Then:

-  The horn switch LED remains dim regardless of what's happening. 

-  The fog light switch is dim with the fog light off or bright with it on - the fog light feed comes from the dipped headlight signal, so only works when the headlights are switched on. 

-  The hazard light switch now flashes bright / off with the side lights off or bright / dim with the side lights on. 

Overall, it looks great and now I'm happy.

Rear Wings and Lights

Still waiting for the throttle bodies to arrive.  Time for fitting the rear wings and lights. 

The reverse and fog lights must have their reflectors perpendicular to the road surface.  In order to achieve this, about 10mm needs trimming from the bottom edge of the casing.  I used a hacksaw to get them roughly where they needed to be, then finished off with sandpaper on the floor to get a consistent edge all the way round.  I used some thin IVA trim around the edge of the light casing and then bolted them into place:

A caution here is that there are 2 negative terminals in each of the light casings and it is very easy to connect the wires incorrecly causing a short circuit.  


Next up, I cut the tadpole trim so that it would bend around the profile of the rear wing and then used contact adhesive to hold it in place.  Other builders have used the panel-bonding agent, but I really don't like it as I find it very difficult to be accurate and tidy when applying it.  Painting the adhesive is much easier.

Once the trim was attached, I bolted the wings into place:

I used masking tape to help line up the positions for the rear light clusters, noting that the suspension isn't quite level...  ...danger, danger!

I made a cardboard template using the backing plate from the light clusters:

And then used it to mark up the positions onto the wings, drilled holes and mounted the rear clusters:

I ran the cable through a support attached to one of the mounting bolts thus:

I have read some chat about putting the electrical connector inside the bodywork to protect it from water, dirt and other contamination thrown up by the wheel, but this would make it considerably more difficult to remove the wing in the future.  I am not sure how often wing removal would need to be done, but I will stick with this set up for now!