Tuesday, November 25, 2008

Some interior, some wheels, some injuries...

Okay, since the motor was installed, and the component board installed, I've done some wiring to almost complete that part of the job. I had to install the potbox (the box that is the go-between from the throttle pedal to the controller), and once that was in I could put the connections from that onto everything else on the board. 

If it seems that I'm repeating myself, it's because I rarely read what I've written previously. Plus, I'm super tired.

So I had my rims sandblasted, but here's how they looked before that.

Pretty bad. So then I had them sandblasted, and then I treated them with the POR 15 pre painting chemicals (1st chemical, wash off with water, 2nd chemical, wash off with water).

Then I primered them with the grey POR 15 paint.

I hope to do the final painting this weekend. I have the stock colors in some rattle cans, plus some clear coat. Doing the two tone deal, with the anthracite (grey) on the outside of the rim, and ruby red on the inside. 

So here's a story for the truly bored: My next step was to get the battery box installed, which was going into the luggage area (behind the back seat.). I've already measure and drilled holes for the install, including the stainless steel 1/8 inch hold straps I made to hold the top of the box down. But back in that area there will be carpet. So my first thought was that I'd just lay down the carpet in the middle of the luggage area, and do the rest of the carpet later.


There's a very specific order in which to do the interior, and before I lay down and glue the luggage area carpet, I have to install the carpet that goes over the wheel well area. Okay, not too big of a deal.

Oh wait. 

Before I install the wheel well carpet, I have to have the headliner (the perforated vinyl wrap that goes over the walls/ceiling/interior of the car) installed, because the bottom of the headliner is glued to the wheel well area, and the wheel well rug is glued over the headliner.


Looks like I'm doing the headliner. At least part of it. Here's how the luggage area looked before any headliner or carpet. All I've laid down is the silver shiny deamplifier material to deaden the sound and help insulate the car.

So to start the headliner, I have to start on the B pillars (the vertical pillars in the middle of the car, where the doors lock to the car.)

I realize that the deamplifier silver stuff looks a lot like dryer duct tape, or plain ol duct tape. It has a tar like substance underneath it, and it's a nice pliable material, that is very easy to work with. I'm really looking forward to experiencing the affect it will have on the noise level. Not that I'll have a loud motor (like the VWs normally have), but it should make for a quiet cabin. I don't have plans for a stereo yet, but do plan on doing something eventually.

The other 'ghetto' looking item you may notice in the photo is the under carpet material there in the panel area. Behind that there is some deamplifier stuck to the body, but there was still space, so I had picked up some of this carpet padding, just a scrap of it for free at a carpet store, for this very purpose. I wanted to insulate this area. Anyhow, on to the next photo of more headliner.

The headliner on the ceiling is the old stuff...haven't done that part yet. Just look at the wall above door stuff. 

Proud of my folds on the area above the drive side window. Wow, I can't believe I wrote that sentence. This project is truly putting me into a weird bubble.

And the back. You can't see the part I goofed up back there, and I'm not telling where it is. Wheel well rug is in too, you can sort of see it, as well as the two 2/0 wire coming in for the battery pack. As I thought about the project after working most of the day on Sunday, I think I have to find new areas for that wire to enter the cabin. In fact, yeah, those holes won't work. What the hell was I thinking.

Trying to do this, while also trying to fit in work time, and hanging out with the family time is really challenging. Both kids want to help so much, but it's not like I can give them the wire strippers and tell them to go for it. Basically I have to completely work out the small tasks I need to do, way in advance of heading out to do it. And I have to know exactly what I'll be doing and how. If I have to improvise something, or make a decision on the design, while also knowing I have to go inside soon to make a sandwich for someone, or get someone down for a nap, I'm probably gonna make a mistake. That's what happened here. 

On Sunday I let me 3 yr old 'help' by holding my iphone. He mostly watched Super Friends on YouTube, but then he discovered the camera, and how to take pictures. He took some great ones, actually, and here's one he got of me...

At the end of the day on Sunday, I finally fit my battery box into the luggage area. Guess what? Now it doesn't fit. F#*@&*@! Is similar to what I said when I realized this. Mostly because that was the goal I had for the day: to fit the battery box into that back area. Well now I'll have to cut away some of the rug that won't be visible when the box is installed, and it should fit fine. I'm very happy that I have not glued any of the big rug piece, just the wheel well rug, and I probably won't have to remove a lot of that. 

A new feature: INURY UPDATE:

My fingertips are really sore, and I had to cancel out on a music rehearsal. Couldn't play guitar at all, and I was supposed to play standup bass for this thing. Not. A. Chance.

New cuts. Almost every cuticle has a deep cut that is irritated when I put my hands in my pockets. But the one I got from my japanese saw (from fitting the supports on the bottom of the battery box), has healed up nicely. I was sure it would scar, as the skin didn't want to join back together. Neosporin really helped out on that one.

My chiropractor thinks I'm nuts, cuz every time I come in I have a new car related issue. This time it will be lower back, on both sides, from reaching around into the back cabin area, thur the rear window, and the other hand reaching up under the back window area in order to try to blindly secure a nut onto a bolt pushing in from the interior. This took WAY too much time on Sunday, and my back hates me for it.

Unrelated to the car, but foot has decided to start hating on me. The bridge of my right foot doesn't like it when I walk. Standing: ok. Walking: bad. Very bad. I'm icing it every night, and nothing is helping. Might have to see the chiropractor early to see if she can help with this one. So because I'm limping, now my hip joint is barking.

Did I mention the rotator cuff/bursitus in my right shoulder. I can't really lift anything heavy, or throw anything or I collapse in a pile of throbbing, aching muscle goo.

Can't wait to start back on the car after thanksgiving.

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