Electrically one structure, yes (unless you really F'd up
).Sounds good. But dedicated grounds for picky or high amp stuff never hurts. Where do the battery negative terminals tie in?
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Last Call Guest on these Group Buy Deal Items from Baja Designs
).
gt1guy
Apparently a racist
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Electrically one structure, yes (unless you really F'd up
Sounds good. But dedicated grounds for picky or high amp stuff never hurts. Where do the battery negative terminals tie in?
The A, both B's, C and the braces that go back, all have welded footprints to the tub. Front B-pillar is literally inside and completely welded to the tub B-pillar, C-pillar is tied into the inner fender in the rear, the trans tunnel is welded to the lower tube that runs between the rear B-pillar and the rear stiffeners for the C-pillar are part of the covers for the rear shocks. So yes, the cage is part of the tub.
Battery neg runs directly to the back of the block at the same spot where the engine harness grounds go.
Winch ground runs to the bat neg. ARB twin runs to the bat neg buss-bar. Alternator ground runs to the back of the block. Cooling fan grounds go to the same spot as the ground that runs between the frame and the block.
Pretty sure all the higher amp grounds are well taken care of. This was all with Bebops guidance.
The ground wires I mentioned in my last post are all really low amp. Horn is just a ground signal for a relay, AEM dash is less the 1 amp, Cruise controller is 3amps, tap shift receiver is less than 1amp, AEM 22ch CAN expander is less than 1amp, the ground for the dash winch control toggle switch is just a signal (I believe), the ground for the cruise dash switch is less than 1amp, the AccuSump bypass ground is 3 amp.
So ~10 amps total. Some of those will never be on at the same time. Don't really see myself using the winch and cruise control at the same time.
Love it 
Super impressive I cant wait to read through all the pages on this
Whats the plan for long term corrosion handling?
We tend to use hot dip gal + ecoat phosphate + powdercoat for everything we possibly can and where we cant cos of precision machined tolerance stuff or because the part is heat treated etc and obviously we dont want to ruin the much time and money gone into heat treating we use Zinc Nickel electro plating minimum of 1500 hour salt certification
Super impressive I cant wait to read through all the pages on thisWhats the plan for long term corrosion handling?
We tend to use hot dip gal + ecoat phosphate + powdercoat for everything we possibly can and where we cant cos of precision machined tolerance stuff or because the part is heat treated etc and obviously we dont want to ruin the much time and money gone into heat treating we use Zinc Nickel electro plating minimum of 1500 hour salt certification
gt1guy
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Love it
Whats the plan for long term corrosion handling?
We tend to use hot dip gal + ecoat phosphate + powdercoat for everything we possibly can and where we cant cos of precision machined tolerance stuff or because the part is heat treated etc and obviously we dont want to ruin the much time and money gone into heat treating we use Zinc Nickel electro plating minimum of 1500 hour salt certification
Thank you Sir.
Reading all the pages is a 9 year journey of me changing my mind and finding out that parts don't fit.
My scientific plan for corrosion resistance is.........................Rustoleum paint. Main reason is that when it gets scratched up, I can simply roll or brush on more. I live where you have to set your watch back 50 years to be on time. There might be someone around here that does powder coating, but I've never heard about them. The other stuff you mentioned, not a chance. Only thing I know they do around here is Fusion Bond Epoxy at the place that preps offshore pipeline pipe.........................and I don't want my parts to be offshore pipeline lime green colored.
gt1guy
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I believe I'm 90% done with the wiring. I think. Pretty sure I am.
Other than the led interior lights on the cage, all the chassis wiring is done. Well, I'm also waiting on more DT connectors, I need one on each side for the front turn signals, everything is cut/stripped already.
The engine harness has two splices that still need to be made, the speedometer wire to the cruise controller, and the tap shift wire to the paddle shifter receiver. But I need to get the engine harness sitting in it's final position before I can do that. Plus, those two wire will need a DT connector added in somewhere.
Then I need to break open the new sack of 500 zip-ties and make both harnesses all loom ready in place, so when I remove them they still make sense. I also need to make sure there's no unconnectored wires connecting them together. I don't think there is but, there's always the chance of finding a "I'll deal with that later" grenade.
I think the biggest job I still have to tackle is the layup of the hood.
Other than the led interior lights on the cage, all the chassis wiring is done. Well, I'm also waiting on more DT connectors, I need one on each side for the front turn signals, everything is cut/stripped already.
The engine harness has two splices that still need to be made, the speedometer wire to the cruise controller, and the tap shift wire to the paddle shifter receiver. But I need to get the engine harness sitting in it's final position before I can do that. Plus, those two wire will need a DT connector added in somewhere.
Then I need to break open the new sack of 500 zip-ties and make both harnesses all loom ready in place, so when I remove them they still make sense. I also need to make sure there's no unconnectored wires connecting them together. I don't think there is but, there's always the chance of finding a "I'll deal with that later" grenade.
I think the biggest job I still have to tackle is the layup of the hood.
WaterH
Well-known member
Did you run any extra wires in your harness? I ran a couple from the console to the rear of the truck just in case I decide to do something back there later. I also ran a couple from my console up to the overhead switches. I even installed a couple extra switches. One is labeled light bar even though I don’t have one. (I’m kind of undecided if I want one) The other is just labeled AUX. In your case, you might want rock lights a lighted stripper statue on the dash.
gt1guy
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No I didn't add any extra wires. I do have two or three unused spots in the SPod. There are also a bunch of unused wires from the chassis harness. I need to deal with those too. Some can't be repurposed, like the tach wire, but there might be a few that are either B+ or switched B+. The wires that could be reused at some point I think I'll just cut a couple feet long/cap the ends/coil them up behind the dash. The rest I'll just cut as short as I can.
I've used all of the acc circuits in the chassis fuse box already for other things.
gt1guy
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- #2,198
So, the new Deutsch DT connectors I ordered were supposed to show up yesterday. UPS usually come by when I'm having my morning coffee...........at 11. I get out to the shop and wait, and wait, and wait, and wait. UPS finally shows up while I'm eating dinner.
So I open the box to check it out. All it has is 10 receptacles and pins. So I start bitching to myself that they ****ed me and go online to check what I ordered. Well, it seems I ordered 10 receptacles. So I started calling myself a ****ing moron......................and then ordered 10 plugs and pins. ****.
I did also get the two pigtails I ordered for the AM Equipment HD windshield washer pumps. so those can get finished off today. I have high hopes for this washer system that is made for busses. Each nozzle has it's own pump.
Also cleaned out the tub so I'm ready for the interior lights when the connectors show up.
I'd like to get this all done and tested before I head back to Saudi in a week or two.
So I open the box to check it out. All it has is 10 receptacles and pins. So I start bitching to myself that they ****ed me and go online to check what I ordered. Well, it seems I ordered 10 receptacles. So I started calling myself a ****ing moron......................and then ordered 10 plugs and pins. ****.
I did also get the two pigtails I ordered for the AM Equipment HD windshield washer pumps. so those can get finished off today. I have high hopes for this washer system that is made for busses. Each nozzle has it's own pump.
Also cleaned out the tub so I'm ready for the interior lights when the connectors show up.
I'd like to get this all done and tested before I head back to Saudi in a week or two.
WaterH
Well-known member
Will you be on a ship again? Where?
That's hilarious on the Deutsche connectors, and awesome on the pay bump and travel pay. Go make some money!
gt1guy
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Yep, I'm always on a boat. It's actually the same boat I was on the last time over there. It was being leased to Mermaid Subsea last time, this time the actual boat owner (Posh) has the job.
I'm not sure where we'll be working. I mean it's one of the Saudi oil fields, but I don't know which one. If I was to guess, I'd think somewhere in the MRJN field. There's a **** ton of work going on there.
EDIT:
This time we are going to be doing construction. Risers, tie-ins. Pretty much sounds like new stuff. I like construction. I just hope they don't load us down with idiot Indian divers.
Last edited:
I read this as drivers at first, and then I thought, “I guess Louisiana has the same problems we do here.”
gt1guy
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Ok, hold that thought on the Indian DRIVERS. Now imagine having to try to get those same people to perform heavy construction underwater. Spools that weigh 50 tons, hanging off a crane that's on a moving/rocking boat.
My job ends up being to run interference so they don't get themselves killed. It can piss you off and be terrifying at the same time.
Here's something funny. I'll use the ROV as my snitch when I have Indians in the water.
It will sound like this..............
Kumar, did you get all the studs in the flange?..........
Roger..........
You put ALL the studs in the flange?..............
Roger...........
ROV, Dive, I need you to fly to the flange and have a look for me.......
Dive, ROV, Do you really want to see?...............
No, but I have to...........
Dive, ROV, Can you see that?...............
Kumar, why can I see 4 open holes with nothing in them? Did you put all the studs in or not?..........
Roger......
Kumar, take off you hat and breath water.............
That exact scenario has played out before.
Then the real problem comes to light when I want to not dive these idiots. If I skip them and keep them in the bell, they become the rescue diver if something happens. Well, that's not good either.
gt1guy
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Headlights and running/blinker lights have received their missing connectors.
Realized that the Mechman alternator doesn't use the 2 wire plug that the PSI harness has for the alternator. Had to dig out the box that the alt came in to find the P101 plug for the harness 2 wire plug. Apparently the Mechman P101 plug makes the ECU think all is good with the charging system. I think that has something to do with the smart charging that some vehicles have.
The Mechman alt is a one wire type that will always put out ~13.5-14v. It actually has a 4 wire plug in the case, but it only uses a single excite wire and the other 3 spots are sealed off.
So, I had to dig through the extra wires leftover from the painless harness and run the alt excite wire from that to the Mechman alt. Spliced that to the connector on the alt and I now have one less extra wire to deal with.
Realized that the Mechman alternator doesn't use the 2 wire plug that the PSI harness has for the alternator. Had to dig out the box that the alt came in to find the P101 plug for the harness 2 wire plug. Apparently the Mechman P101 plug makes the ECU think all is good with the charging system. I think that has something to do with the smart charging that some vehicles have.
The Mechman alt is a one wire type that will always put out ~13.5-14v. It actually has a 4 wire plug in the case, but it only uses a single excite wire and the other 3 spots are sealed off.
So, I had to dig through the extra wires leftover from the painless harness and run the alt excite wire from that to the Mechman alt. Spliced that to the connector on the alt and I now have one less extra wire to deal with.
gt1guy
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- #2,206
Fuel cell is up next. Will need to figure out a way to hang the fuel pump off the fill plate. Would like to make as much of the plumbing inside the cell out of hardline, though I "think" it would be wise to have at least a small section of flexible line in the mix somewhere due to the fact that I'm running a Hydromatt.
Already have the wires ran and connected for the fuel level sender. Fuel pump wires have been ran to the cell with long tails. Still have to add the penetrators for the pump wires to the fill plate.
I assume there shouldn't be a problem with welding a pump hanger to the bottom of the fill plate? I rather not have two more bolts going through the plate that need to be sealed.
Already have the wires ran and connected for the fuel level sender. Fuel pump wires have been ran to the cell with long tails. Still have to add the penetrators for the pump wires to the fill plate.
I assume there shouldn't be a problem with welding a pump hanger to the bottom of the fill plate? I rather not have two more bolts going through the plate that need to be sealed.
gt1guy
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Apparently, some parts shouldn't be bought 12 years in advance of needing them. 
Popped off the cell fill plate, a cell that has never had a single drop of fuel in it, and found the foam completely falling apart.
Just reaching down the hole for the level sender I can feel the bottom of the cell covered in this ****.
My understanding of fuel cell foam was always that over time, gas would degrade it, and that when it moved around inside (keeping the fuel slosh in check) it would rub little bits away as it came in contact with the sides of the cell.
None of that has taken place in this cell........... only time has taken place.
Maybe this is to be expected with so much time passing. Sure caucht me off guard though.
I guess it time for new foam.
Popped off the cell fill plate, a cell that has never had a single drop of fuel in it, and found the foam completely falling apart.
Just reaching down the hole for the level sender I can feel the bottom of the cell covered in this ****.
My understanding of fuel cell foam was always that over time, gas would degrade it, and that when it moved around inside (keeping the fuel slosh in check) it would rub little bits away as it came in contact with the sides of the cell.
None of that has taken place in this cell........... only time has taken place.
Maybe this is to be expected with so much time passing. Sure caucht me off guard though.
I guess it time for new foam.
gt1guy
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- #2,211
Ya, I was surprised to see that the stuff will die just on its own.
So right now I'm thinking about simply not putting any foam back in. There are a **** ton of vehicles running around with large tanks and no issues. I'm also not racing or following a rule book, I don't HAVE to have foam in there.
Doing a bit of research on how to deal bladder foam turns out to be just about the exact opposite of how I'd treat this thing. The Jeep will sit for months at a time with whatever level of fuel is in the tank when I go to work. Apparently the foam doesn't like that.
Woke up today to emails saying I'm leaving for work on thurs. I sure as **** wouldn't want to have to drain 20 gallons of gas out of the Jeep as part of my get ready for offshore routine. That really got me to thinking is this something I want to deal with and the answer is a big fat no.
Anyone who's dealt with fuel cell foam want to share any things you've learned?
Ranch Hand
Well-known member
Wait a minute. You work in the Persian Gulf, right? So, you just fly in and offshore pipeline work is going on like normal? You're getting hazard pay, I hope.
I called that one pretty good. Says 7/2014 on it.
That was when I started collecting parts for the build. Two years before I even had the shop and two years and 10minutes before I started cutting up the Jeep.
Pull it out, vacuum the tank out and call it done. Putting foam back in is just asking for trouble.
gt1guy
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Yes, I work in the Persian Gulf. Work has been going on there this whole time. There could be certain spots where they have stopped working, but I haven't heard anything like that. In fact, I have a buddy who lives about 20 mins from me who is on the same flight over. He's working for a different company on a different job.
I look at it like this....The oil fields are gigantic and Iran doesn't give a **** about a single platform or boat. Pretty sure they are more interested in the big grey ships making their **** blow up.
I feel safer going to Saudi while drones and missiles are flying, than I ever did going to Nigeria.
No hazard pay, got a $200/day bump in pay, just a different company though.
I fly to Doha Qatar and then catch a short flight to Damamm Saudi.
Now watch, I'm going to get there and all hell will break loose. You just voodooed me.
Ranch Hand
Well-known member
Yes, I work in the Persian Gulf. Work has been going on there this whole time. There could be certain spots where they have stopped working, but I haven't heard anything like that. In fact, I have a buddy who lives about 20 mins from me who is on the same flight over. He's working for a different company on a different job.
I look at it like this....The oil fields are gigantic and Iran doesn't give a **** about a single platform or boat. Pretty sure they are more interested in the big grey ships making their **** blow up.
I feel safer going to Saudi while drones and missiles are flying, than I ever did going to Nigeria.
No hazard pay, got a $200/day bump in pay, just a different company though.
I fly to Doha Qatar and then catch a short flight to Damamm Saudi.
Now watch, I'm going to get there and all hell will break loose. You just voodooed me.
Pack your gris-gris bag.
gt1guy
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- #2,218
Finally got my flight details. Leaving tomorrow. Taking a different path there than normal. This time I go to lovely Atlanta, then to Abu Dhabi, then fly into Dammam, Saudi. I told them I wanted business class, maybe this is what I get when a Indian is booking flights.
Long flight is on Etihad airlines. Buddy said they were nice, we'll see. I like the pods on Qatar airlines.
Long flight is on Etihad airlines. Buddy said they were nice, we'll see. I like the pods on Qatar airlines.
I couldn't imagine being locked in a plane with 150 other passengers that don't believe in deodorant.
I have flown Etihad, flew them to India last year and will again this September. I've never flown Qatar, but Etihad has the pods in business too.
