====================================================================== | FORD XR RALLY INSTRUMENTATION ====================================================================== | Author: Skye Poier This documents describes the electrical and mechanical controls to be installed in the cabin of the rally car, to provide a high level of control and feedback to the driver and co-driver. Gauges and warning lights are chosen according to the type of feedback required; gauges for specific information, warning lights for general. Knowing the exact oil pressure is little use on a stage; knowing oil pressure is below 20 psi is useful (possible impending doom). Sources: my brain, rally prepared sapphire at JVAB, SpecialStage forums, wise crusty rallyists, Rallying: A Practical Guide | SECTION I: Functional Listing by Type ---------------------------------------------------------------------- | SWITCHES -------------------------------------------------- a/b/c indicates n-position switch with 0=off (toggle type) + indicates high current switch * indicates lighted switch (rocker or push type) 0/1 parking lights 0/1/2 main (outer) beams off/low/high 0/1 driving (inner) beams 0/1 aux lights button horn (in parallel with steering wheel push, if fitted) 0/1/2 wipers off/low/high (front only) 0/1 wiper fluid pump (front only) 0/1 2x fuel pumps (on ign/off) 0/1 radiator fan (thermostat override) 0/1 + ignition (keyed) 0/1 + battery (keyed) with alt. kill button + starter? 0/1/2/? heater fan off/low/hi 1/0/2 left/off/right turn signals 0/1 navigation computer 0/1 intercom 0/1 * hazards 0/1 * interior light & map light 0/1 Ejection Seat (co-driver side only) 0/1 Oil slick 0/1 Machine guns (rear firing) 0/1 Hub cap blades (retracable) 0/1 Rear window armour 0/1 Smoke screen | LAMPS -------------------------------------------------- . oil pressure warning . battery (ignition) . turn indicators | GAUGES -------------------------------------------------- . speedometer . tachometer . boost pressure . petrol level . coolant temp . fuel pressure . oil temp . oil pressure . voltmeter | RELAYS & FUSES -------------------------------------------------- MY Relay List: loads: r - resistive, m - motor, i - inductive 30 outer (main) beams high (5 term) 30 outer (main) beams low (5 term) 30 inner (driving) beams (5 term) 30 aux beams 30 horns 30 wipers 30+? ignition switch 30 radiator fan 20 x2 fuel pumps 20 stop lights - long run, small switch - indicator/hazard flasher relay TODO stock or generic? mount? +++++++++++ - starter relay (engine bay) = 11 total MY Circuit Breaker (replaces fuses) List: 30 ignition 30 headlamp high beam 30 headlamp low beam 30 driving lamp 30 aux lamps (pod) 30 wipers 20 heater blower, w/s washer 20 engine fan 20 horns (Hella) 20 interior lamps (map light, cockpit light) 20 nav computer, intercom 20 parking lamps, tail lamps, side marker lamps, underhood lamp(?), license lamps 15 EEC 15 stop lamps, backup lamps 15 x2 fuel pumps 10 hazard signals, turn signals 10 instrument lights, gauges, warning lamps = 6 x 30A, 6 x 20A, 4 x 15A, 2 x 10A = 18 total Note: relays are an inductive load Use terminal strips for junctions? Stock - splices in the loom YES, and oversize butt/etc crimp connectors. Dual parallel main supply fuse (see: Preparing Sierra) Main - Fuse Link B - 14 GA green rating?? EEC - Fuse Link A - 18 GA brown rating?? NO, replace with CB's above -- Stock XR fuse box: http://www.rallyrace.net/images/xr_box_1.jpg Relay 1 - A/C Temp Switch - Relay 2 - Horns Relay 3 - A/C Clutch WOT Cutout - Relay 4 - Fuel Pump Relay 5 - Fog Lamps - Relay 6 - N/A - Relay 7 - Interval Windshield Wipers Relay 8 - Stop lights Relay 9 - Seat Belt Reminder - Relay 10 - Ingition Switch Relay 11 - Rear Window Wiper - Relay 12 - Interior Light Delay - Relay 13 - Rear Window Defogger - = 12 total - Ratings: estimate based on fuse value - Stock wiring does not have headlamp relay?!? .. Fuse 1 30 - Power Windows, Cruise Control, Power Door Locks Fuse 2 30 - Rear Window Defogger Fuse 3 30 - Windsheild Wipers Fuse 4 30 - Heater Blower, Rear Wiper, W/S Washer, A/C Switch, Engine and A/C cooling fans Fuse 5 10 - A/C WOT Cutout Relay, Backup Lights Fuse 6 15 - Horns Fuse 7 15 - Stop Lights Fuse 8 10 - Clock, Aux Warning Module, Instrument Cluster, Gauges, Bulb outage module, Interior LT Delay RLY Fuse 9 15 - Hazard SW, Turn signals, Turbo Overboost buzzer, Dual Warn Buzzer Fuse 10 15 - Fog Lights Fuse 11 30 - A/C Temp Fan, Power Door Locks, Power Mirrors, Heated Seats Fuse 12 25 - Courtesy Lamps, Cigar Lighters, Vanity Mirror Fuse 13 10 - Hazard Flashers, horn relay Fuse 14 10 - LH headlamp high beam Fuse 15 10 - RH headlamp high beam Fuse 16 10 - LH headlamp low beam Fuse 17 10 - RH headlamp low beam Fuse 18 10 - LH front parking lamp, LH tail lamp, rear side marker lamps, underhood lamp, license lamps Fuse 19 10 - I/P illumination control, RH front parking lamp, RH tail lamp, front side marker lamps Fuse 20 15 - Fuel pumps = 20 total -- 1985 Manual 43-30-3: 6 x 30, 2 x 25, 4 x 15, and 8 x 10 amps. 30 amp fuses are lt. green, 25 are "natural", 15 are lt. blue, and the 10 amp fuses are red. -- 89 XR: 5 x 30, 1 x 25, 5 x 15, 9 x 10 amps Driver's side of engine compartment 30A 25A 10A 10A 10A 10A 10A 10A 10A 15A 15A ? 15A turn signals 10A gauge ? 15A ? (brake lights?) 15A horn 10A brake light? 30A radiator fan 30A windshield wipers 30A rear defroster 30A elec. windows? for those across the top on driver's side (above) (these are positions 11-20): 30A = heated seats 25A interior lights? 10A = emergency flashers 10A = high beam 10A = high beam 10A = low beam 10A = low beam 10A = ? (rear taillight?) 10A = ? (rear taillight?) 15A = fuel pump? fuel gauge? | MISCELLANEOUS -------------------------------------------------- . panel light rheostat . heater temperature control . heater output direction control . brake bias adjuster (later) . wheel sensor for computer (3x - L,R redundant plus jumper to computer connector) . flexible navigator map lamp (red) . lighter socket (might be handy for plugging in accessories off-stage like flashlights, radio, etc) or 1/4" mono jack? . affix panels with quick-release fasteners . low-intensity console panel lamp, to illuminate non-lighted switches during night stages without blinding the driver and codriver. (OPTIONAL - may not be necessary) . intercom jacks | SECTION II: Layout ---------------------------------------------------------------------- +--+ +-----------+ +--+ +------+ |1 | |2 | |3 | |4 | +-----------------+ +----+ | | | | | | +------+ |6 | |7 | +--+ +-----------+ +--+ +------+ +-----------------+ +----+ |5 | +------+ +--------+ |8 | | | | | +--------+ #1 - stock, 3 switches + heater vent switches UNUSED 0/1 fog lights 0/1 rear defrost 0/1/2) rear wiper, jets (hold on) 1x expansion slot #2 - stock, gauge cluster gauges, STOCK speedometer (mph) petrol level coolant temp boost pressure tachometer warning lamps, STOCK UNUSED high beams oil level (?) parking brake warning lamps, STOCK turn indicators battery (ignition) #3 - stock, heater controls heater temp heater direction control TODO - can't find it in the pile??? .. uses vacuum control. TODO eliminate??? #4 - stock, heater vents (2x) #5 - custom, upper controls panel, was: clock and warning lamps W 212mm x H 101mm w/ "soda cap" radius corners gauge, fuel pressure D 2 1/16" (53 mm) gauge, voltmeter D 2 1/16" (53 mm) switch, fuel pump #1 switch, fuel pump #2 switch, rad fan warning lamp, oil pressure red 1/2" LED TODO finalize support brackets DONE spacers - H 150mm (9/16) ID 8mm (5/16) rubber or nylon. make from pucks? http://www.keyelco.com/kec/standpro/prodcopy/prod32.htm or spacers... 1/2" thick Polypropylene - good chem resist, 135C max temp HDPE - good chem resist, 120C max temp http://www.bibby-sterilin.com/bibby/cat/azlon/intro.htm http://www.protoblock.com/news.html 1/2" thick HDPE 11x12" RECV'D #6 - custom, was: glove box W 290 mm x H 76 mm Make it removable so the whole thing can be removed with computers and all when the car is parked. switch, navigation computer navigation computer Fabricate mounting bracket for navigation computer and map light (?) Mounting for ECU? Or stock location (nav footwell)? Harness length.. Spare bulbs, fuses, misc small critical storage. Mount nav light behind nav on cage (see: Practial Guide) if possible #7 - stock, heater vent #8 - custom, lower controls panel W 31 cm (top) x W 29 cm (bottom) x H 30cm (to tunnel metal) Fold over edges to prevent cuts in an accident, if possible. or: use std controls shroud? Cut to glovebox? YES cut & mount alum panel TODO switch, heater blower control (STOCK) relays fuses TODO finalize Stock Stalks: (use 'em!!) indicator control wiper off/low/high wiper fluid horn (if fitted to steering wheel) main beams hi/low eliminate: stock hazard switch. It's flimsy plastic, and its behind the steering wheel where it's hard to reach. Black plastic or alum or steel for custom panels. Panel material - find something at Industrial Supply Krylon Industrial Tough Coat - 3725 Semi-Flat Black Switches and other controls should be spaced for easy operation even when wearing gloves. Black "craft felt" fabric glued to all upper dash areas to reduce reflections on windscreen. Min size: 21" x 72" (6 ft) DONE Brush contact cement for tight areas, spray for large flat areas Interior light(s) Aircraft Cockpit light - Soderberg S1990 12V Dzus fasteners for panels #5, #6 and #8 alum panel thickness - 1.2mm (.047") 4x ASHJ4-85 SS SE, SR4SS, S4-200 (w/o SE) -75, " , " or Phillips head APRJ Easier-to-find-list: 4x AJ4-75 upper stud 4x AJ4-35 lower stud 4x S4-200 upper spring 4x RP4-300 lower right-angle spring plate 8x SR4SS snap ring Ahhh forget it!! Impossible to find!! Get cap head hex recess bolts from McMaster-Carr instead with captive nuts. http://www.racerpartswholesale.com/dzus.htm 1-800-267-8997 Gould Fasteners (Canada) www.wescoair.com (USA) Auburn - (253) 939-1881 100pc min :( www.pentacon-inc.com DFCI suggests: Pentacon Aerospace in Chatsworth CA, tel 818 727 7800 or S.W. Anderson Co. in Downers Grove IL, tel 630 964 2600 High Power Horns Hella 85104 Dual Compact Trumpet - 12 A Hella 85105 Dual Air Horn - 25A (30A relay) YES $30 Rallylights.com RECV'D Leave room for future expansion! | SECTION III: Operating Specifications ---------------------------------------------------------------------- All connections to be crimped. LIGHTS ------ Headlights are H4, high/low in the main position and H1 in the drive inboard position. http://www.rallylights.com/hella/standard_bulbs.asp The following must turn on automatically with parking lights and be controlled by dimmer knob: . dash lights . lighted switches . gauge lights GAUGES ------ Electrical senders for all gauges FP gauge sender (electrical) at pump/filter in wheel well Oil pressure & temp senders (electrical) at remote oil filter housing VDO Cockpit Series ----- Oil Pressure 100 PSI Electric (350-065) use instead of FP gauge, only difference face label? YES Voltmeter (332-041) Oil Temperature 300 F Electric (310-012) http://www.racerpartswholesale.com RECV'D ++ Oil temp sender 300F M10x1 spade terminal Single Station 323-423 ++ Oil Pressure gauge electric 80psi (5.5bar) VDO 350-040 sender M10x1K 80psi 7psi warn 30/2 360-006 M10 tap at remote filter head for oil temp & oil pres can chase 3/8-24 threads to M10x1 100psi no M10 sender :( 150psi (10bar) available 350-041 sender 360-023 too high VDO gauges need 2-1/16" hole saw aka 52mm hole saw Milwaukee 49-56-0121 Super-Tough Bi-metal Hole Saw will work with my arbor 49-56-7150 http://www.weldingmart.com/ $6.44 + 11/32 .3mm too small (9mm) drill for LEDs 15/32" (12mm) drill for toggles and CBs 5/8" (16mm) drill for horn button 7/8" (22mm) drill for batt switch all RECV'D from pis. Reblight has adjustible senders for oil pressure lights. And large and small lights in several colors. This way you can have a small warning light at, say 40 lbs, and a large one at 10 or 15 lbs. If you run 20 miles at 7000 rpm and 20 lbs of pressure the stock oil light may not come on but damage is being done. #1 Unibit Step Drill This 1/4" hex shank quick change high speed steel bit might not do it all but it comes pretty close - 13 different holes sizes in 1/32" increments for drilling in 1/8" maximum thickness. Hole sizes: 1/8", 5/32", 3/16", 7/32", 1/4", 9/32", 5/16", 11/32", 3/8", 13/32", 7/16", 15/32", and 1/2". WARNING LAMPS ------------- LED viewing angle: approx distance from eye to dash: 80cm max to right,k 40 cm, max down, 40cm.. ~30deg Isilon red LED - lumex.com SSL-LX2573SRD 35mcd " blue LED - SSL-LX2573USBD 80mcd Dialight: http://dialight.frontex.com/products.tpl?page=optoelectronics&cat=Panel&sub=LEDPMP 609-2112-130 red 12V 15mA 20mcd 9mm mount 8.89mm lens hooded - newark 609-2212-130 green 609-2312-130 yellow "609 series" - newark not hooded - 609-1112-130 red 609-1212-130 green 609-1312-130 yellow Quantities: 1x red LED lamp + some extras, they're cheap CONNECTORS & WIRING ------------------- low voltage - high voltage - Packard Weather Pack double row terminal strips with jumpers and push-on adapters? TODO - wheel sensors - bnc? coax? check brantz Wiring Sizes: 16 AWG for 10A up to 22ft 14 AWG for 30A up to 12ft use 14 for general low draw, use 12 for motors & lamps & long runs, and 10 for headlights Solid core OK - At DC and for practical purposes low frequencies like power line AC, skin effect is non-existant. http://www.rallyrace.net/docs/autowiring.htm Quantities: wire - industrial supply RECV'D heat shrink spade (quick) connects 1/4" heat shrink gun (buy @ waytek) SWITCHES -------- General switch rating - 10A 12V * Anything over 10A should be on a relay Starter button - 35-60A Battery switch - 175 amp continuous, 800 amp intermittent, keyed racerparts.com - RECV'D Ignition switch - ? Switches should be sealed from dust and moisture. Quantities: buttons - horn reset start - waytek reg toggle - drv aux fp1 fp2 rad nav com - waytek lit toggle - haz int rear - waytek RELAYS ------ See also docs/relay.txt Fiat modular DIN relay mounts? NO - normally open circuit (not energized) NC - normally closed only SPDT will have both Orientation sensitive? NO Bosch: Use M3 micro relays for everything. Higher density, similar price. Use highest rating/5-term for interchangability. 11 x 30A - buy waytek FUSES ----- http://terminaltown.com/Pages/Page107.html ** ATC fuse breaker replacements Tyco: W58 cb = 8 x 30A, 6 x 20A, 3 x 15A, 4 x 10A - buy digikey MISC ---- Fuel pumps: < 10A (to ~50psi) Labelling: use work Brother PT-15 3/8" white on clear TC14Z1 3/8" white on black TC-34Z (2pk) OR... buy PT-2300 off ebay and use 1/4" white on black TZ315, and can hook it up to the computer via USB. Cutting alum. panels: Bosch 1587AVSK jigsaw RECV'D Need: T227D: ideal for curve cutting in alum 3/16" to 5/8". Plastic 3/16" to 1-1/4". Non- ferrous metal, metal 3/16" to 1/4", fiberglass, lead, tin 3/16" to 3/4". MATERIAL: HSS www.northwestpowertools.com/tool_manufacturers/bosch/acc/jigsaw/jigsaw.htm Came with: T118A: For thin material Straight cuts in metal, non-ferrous metal, aluminum, sheet metal 1/16" to 1/8". MATERIAL: HSS T101DP: Ideal for parallel and angled cuts Straight cuts in hard and soft wood, plastics, particle board 1/4" to 2-3/8". Use parallel guide. MATERIAL: HCS T144D: Ideal for straight, parallel cuts Very fast, clean cuts in hard and soft wood, particle board 1/4" to 2-3/8". Suitable for plunge and curved cutting. MATERIAL: HCS Home Depot (206)467-9200 (Lander St) Lowe's (206)366-0365 (12525 AURORA N) PIS 206-682-2100 sat9-3 Mini-Max Storage (206) 282-7555 sat10-5 Tool Town 281-1166 m-f 9-6 sat 10-2? Do everything (or as much as possible) in Metric, thank you! 25.4 mm/inch | SECTION IV: Reject Pile ---------------------------------------------------------------------- Autometer Z-Series ----- Ful Pressure 100 PSI, 2 1/16", ATM-2659 XX RECALLED XX Notes: Fuel Press 100 PSI (Electric) http://www.egauges.com/vdo_bld.asp?Series=Z-Series#Fuel Pressure Gauges $74 http://www.dieselmall.com/search_result.asp?CATEGORY=ALL&MANUFACTURER=ALL&DESCRIPTION=&PRODUCT_ID=ATM2659 $69 Z-series Oil temp ATM-2639 (140-300 F) summit - $42 Z-series Voltmeter ATM-2645 summit - $34 Painless LED 1/2" (13mm) - $9 summit LEDtronics: PT501T-0UR-014V-W6 - 8mm mount diffused shroud - red PT501T-0UO-014V-W6 - " orange No small quantities... scratch that idea. DIMMER http://www.autoengcorp.com/9040.html EL Panel lighting (probably not needed) http://www.aircraftextras.com/EL-Panel1.htm http://www.beingseen.com/ ======================================================================