Beginning to deal with the electrical system in# 209...

[Rupunzell]

Lampredi TC nearly did, Mazda Millenia Denso alternator conversion did, block/head/oil system and related did.. What remains is install the cylinder head & oil pan..

Moving on to the Scorpiacarlo electrical system ....

Looking at the wiring diagrams... about 50% of the wiring and 'lectrical system is for 1970's smog. There has got to be pounds of extra wiring and stuff just to deal with all that smog stuff.. Pondering to remove all of that, re-wire the entire chassis, or do a remove what is not used then add what is needed. What will be a given, the primary motor systems, Fuel, ignition, starter, alternator will be re-designed and done from scratch. These are considered "cannot fail" systems
which require high quality electricals and methods/practice common to aerospace and space fight systems.. Teflon insulation silver plated copper wire, Sensata hermetic sealed magnetic breakers, hermetic sealed aero spec connectors, controlled crimp terminals and all that..

Bernice

 

[NigelProdrive]

Do the hybrid system removing what you don’t need and keeping what you do. Remove gizmos no longer needed or trace hanging connector wiring back to fuse box. You’ll be working through the hole into the engine compartment, the driver’s sill and fuse box a lot. Wire the engine compartment wiring in a loom on the crossmember instead of up on bulkhead for shorter lengths and hides it better.

Keep a box of all the wiring you removed until the end to weigh to let us know how many pounds you removed.

 

[Derek Greenwood]

Do the hybrid system removing what you don’t need and keeping what you do. Remove gizmos no longer needed or trace hanging connector wiring back to fuse box. You’ll be working through the hole into the engine compartment, the driver’s sill and fuse box a lot. Wire the engine compartment wiring in a loom on the crossmember instead of up on bulkhead for shorter lengths and hides it better.

Keep a box of all the wiring you removed until the end to weigh to let us know how many pounds you removed.

I need to do this. I am not looking forward to it

 

[NigelProdrive]

In doing mine many many years ago, I blew up the wiring diagram and relay sheets as large as possible on paper. Then white outed the wires and devices as I removed and highlighted wires I kept while verifying. And drew in additional to make my simplified diagrams. These days some of you can probably do on a computer.

Also consider changes to or deleting the oil pressure to fuel pump relays, wiring both cooling fans for cooling separate from the old AC fan wiring, oil cooler fan by thermostat, air fuel ratio meter, fuel cutoff switch, racing battery cutoff switch (on dash or inside glove box) good for easy cutoff to not drain during winter, security system thieves won’t know about or emergency cutoff, hidden amplified radio antenna, ….

Wire tuck tail light wiring hidden inside the driver’s 1/4 panel.

 

[Rupunzell]

In doing mine many many years ago, I blew up the wiring diagram and relay sheets as large as possible on paper. Then white outed the wires and devices as I removed and highlighted wires I kept while verifying. And drew in additional to make my simplified diagrams. These days some of you can probably do on a computer.

Also consider changes to or deleting the oil pressure to fuel pump relays, wiring both cooling fans for cooling separate from the old AC fan wiring, oil cooler fan by thermostat, air fuel ratio meter, fuel cutoff switch, racing battery cutoff switch (on dash or inside glove box) good for easy cutoff to not drain during winter, security system thieves won’t know about or emergency cutoff, hidden amplified radio antenna, ….

Wire tuck tail light wiring hidden inside the driver’s 1/4 panel.

Once the current motor and transaxle is out of# 209, this "fun" begins. The fuel tank (project in it's own) comes out as does the coolant tubes (have SST ones from Brown & Miller to replace them), AC hoses and all that.

The smog wiring will be removed with their related bits attached, bit by bit to the fuse box.. then dumped into a box.. Based on the wiring diagrams, majority of the rear wiring harness will be gone.

The two fuel pump relay scheme has good intentions but problem prone. Oil pressure switch was intended to prevent motor failure due to lack of oil pressure .. except if anything goes a bit wonky, fuel pump stops running leaving the Scorpiacarlo stranded and not easy to diagnosis.
Solution to that designed in problem... rip all that out, replace it with a direct fuel pump power to the circuit breaker then battery. No relay, nothing else in that circuit. Same with the electronic ignition.

Those old fashioned European style fuses will be removed, replaced by aero spec circuit breakers. Those stamped metal fuses with stamped metal holders are NOT reliable.. This style of fuse was used on the majority of European cars from that era with no exceptions.

Instead of an FIA spec kill switch with a rated capacity of 100 amps.

This EV contractor rated for 500 amps at 1,000 volts will be used.

There will be no ignition key switch, it will have some other means to turn on main power via the contractor..

As a tribute to Kimera, there will be a start up set up like this including the two starter motor buttons. Too good to ignore.

Before all that sourcing and obtaining the proper electrical bits are the to-do item,
Bernice

 

[beezee]

Why the 1000V contactor? Is it just something you had available?

 

[Rupunzell]

Why the 1000V contactor? Is it just something you had available?

Not the 1000 volt rating that is significant for the electrical system in# 209, it is the 500 amp contact rating that is significant.
Has a mechanical cycle rating of 1,000,000 cycles, cycle rating of 10,000 switching 200 amps. When used in a vintage moto application these EV contactors should last/work ok.

This contactor will be used for main power much like a FIA regulation kill switch which is manually operated. The EV contactor allows operation by very small switch..

Beyond the EV contactor, there will be aero/space flight grade electrical components and wiring methods.. example:

some info on wire and more:

Wire selection and ratings, an introduction | Corsa Technic

Motorsport electrical products: OEM and hard to find terminals and connector kits, wiring, harness supplies, tooling, and sensors for modern and vintage motorcycle, automotive applications. Easy online shopping, low cost shipping options, to expedited around the world. We accept Paypal and...

www.corsa-technic.com

PTFE wire (more than 200% safety factor) will be used for wiring re-do on# 209.

There will be zero tolerance for electrical issues of any kind. This has been did in the LeMons racer as the electrical system was designed and built from scratch. There has been zero failures or electrical issues with the LeMons racers since day one and for over one decade of LeMons racing.

Electrical issues can be prevented and a rare occurrence.
Bernice