Some detail here on home made pulleys.

http://www.clubcobra.com/forums/aust...-steering.html

Top thread, as always, Mike.

Anyway, the solution to my alternator issues was far less elegant than yours I'm afraid.

I did manage to get the clutch pulley of with a 17mm Inhex on the rattle gun. It turns out is is a reasonable standard shaft and threaded end, thankfully.

I popped into my local auto elec, introduced myself, told I'm I was building a kit and he cut me off and said he doesn't have the man power to rewire looms for kit cars! Hah! Must have had a bad experience! Or knows how long it takes - that's my next job so I was a bit worried... :)

Anyway, he was in fact very helpful and dug around and found to candidates pulleys for my alternator, both a little worn, that I could try. No charge! Top bloke!

I made the one that was slightly larger fit, with a few spacer washers. It is only about 4% oversized but after the warnings about over revving and burnout on gm alternators, this can't hurt.

I cleaned it up, gave it a dip in the black engine enamel paint tin, and Bob's your uncle!

Im a little concerned about the one turn of thread still exposed on the retaining nut, however it is a reasonably large flange nut and I've used a good dose of locktight. I'm think I might either twist wire it or dollop some glue on the top just in case. That pulley obviously turns clockwise so it help to keep it tight.

And as you can see the clearance is actually excellent.

http://i1372.photobucket.com/albums/...psw7srkkoi.jpg

looks like it was a easy fix in the end , if you have used loctitite and direction of rotation is always spinning the nut tighter i dont think you will haves any probs with it coming loose .
cheers dean

Next challenge, the loom.

http://i1372.photobucket.com/albums/...ps6t9ncklg.jpg

Managed to reroute the loom behind the block so I can mount the ECU behind the dash. Extended the maf lead. All the connectors are connected now. Starter motor in. Now just to tidy it all up.

http://i1372.photobucket.com/albums/...pso1luuvrm.jpg

Here's how to extend your loom one wire at a time. Or at least how to cut and insert an extension. Not too scary really. Just very time consuming! And for what appears a relatively monitor change, I've already used an extra 10m of hookup wire!

http://i1372.photobucket.com/albums/...ps6wmygq1y.jpg

Looking good, and this can lead to one more thing being marked off the list...

https://farm9.staticflickr.com/8884/...735f92_b_d.jpg

Ha ha Craig! Yes, I noticed that I included my whiteboard after I posted!

Or where you just showing off your photoshop skills too! :)

Well done Guy. I was always a fan of "tinning" each end first as I would normally burn my fingers holding them together whilst the solder cooled :-)

Nothing like a good whiteboard to keep you organised. Most (IT guys) can't speak without one :-)

Cheers Gregg

thats were im am going wrong i dont have a white board , thats it first business on the day is off to office works .. looking good guye just dont use all the some color wires lol

Nice work, love wiring. I need a whiteboard as well....

I've been using a spreadsheet and detailing to the level of work needed.

Like minutes I'd date version, strike out jobs as completed and on the next iteration delete the previous strikeouts and add the new job strikeouts.

Though at times slow to see progress, I find it satisfying to be able to eventually rule out jobs and whittle down the list.

Trouble is once I am on the road my next lists will be marked Stage 2, Stage 3........Stage 10.

Still it keeps me occupied.

Seems you've done alright without one so far Dave

Great work Guy, you are making great progress, now that your rotor here, should be on the road soon. Thanks for all your build tips, I went straight Bunnings picked up a white board after your visit on Saturday : )

Sometimes the simplest things are the best things...... A whiteboard. Sure will be a better option that the odd bits of paper at each area that I have now.

Yes, I do love my whiteboard. It is huge, heavy, magnetic. It actually forms part of the wall cladding! It was one of the few things I salvaged from a failed business investment - managed to pinch it out of the boardroom before they totally closed down shop! :-)

And to explain Darryl's rotor comment, some of my parts where shipped down with his kit! Thanks Darryl and AP.

This might be one of my last posts now for a while as I am off to Las Vegas, Miami, Mexico and Cuba for a little trip.

Las Vegas - Shelby Amercian visit and hopefully Shelby Super Snake drive.
Miami - special guests at a Marlins baseball game.
Mexico - pickup some more Mickey Thompsons perhaps?
Cuba - smoking with Castro.

Guy,
If your in Miami, a very short drive up the coast will get you to Backdraft Racing, well worth the visit at Boynton Beach.
Dave

OK, back into again. Been going a little slow - the body is struggling with the cold after the heat in Cuba and Mexico!

A few items ticked off the whiteboard like some more panels, the windscreen water 'bag', air intake setup, radiator and plumbing, fuel level sender, and running the loom into the cabin.

Air intake:

http://i1372.photobucket.com/albums/...psplee4htd.jpg

Radiator and plumbing:

http://i1372.photobucket.com/albums/...psqcw9wyww.jpg

Loom:

http://i1372.photobucket.com/albums/...psbomyuqlz.jpg

Our local Cobra Car Club of Victoria ran a shed run the other week, and stopped by my place. The court I live in was chockers of cobras; impressed the neighbours.

http://i1372.photobucket.com/albums/...psa9dy3z74.jpg

http://i1372.photobucket.com/albums/...psnylyf9nm.jpg

Wiring the loom and gauges
 

I was right to concerned about the wiring loom. That's what most of my time has been spent over the last few months.

http://i1372.photobucket.com/albums/...psm7qugalg.jpg

Here's a few time lapse pics of the dash prep.

http://i1372.photobucket.com/albums/...psb4xfwn5r.jpg

http://i1372.photobucket.com/albums/...ps3hws8tct.jpg

And the fuse panel.

http://i1372.photobucket.com/albums/...pszgml9clj.jpg

But I've finally got it all working. Plugged in the OBD2 scanner and voila - errors codes as expected (for things I don't have connected!) when I get the ecu reprogrammed that'll get fixed.

http://i1372.photobucket.com/albums/...ps9lkadwsa.jpg

It did give me a warning that my fly-by-wire accelerator wiring was wrong, and I checked it and sure enough I'd got the bottom row of wires back to front. Duh!

Once fixed, the scanner shows the accel position nicely! Graph goes up and down with pedal pressure.

http://i1372.photobucket.com/albums/...psipsom0le.jpg

Now all I need are my headers and I'll be able to get this baby fired up!

Very tidy Guy. Looks great.

regards

It still astounds me how good these things look.
Pace have certainly changed the game forever.

Pace
 

Absolutely Ash...