Differential Vent, Battery Box, Fuel Tank and Electrical System

I finally received the differential vent fitting I’ve been waiting for. It’s a press in fitting (unlike the threaded fittings used on the solid axles). I used some high-temp thread locker and drove it in, then fit a vent riser with check valve at the top. I’ll use an adhesive zip-tie base to secure the top of this and keep it upright.

After installing the battery box, I reinstalled the battery (hopefully for the last time before the go-kart stage).

My dad and his friend Larry helped me lift the fuel tank and get the straps installed.

Jenn came out and we spent some time working on the electrical system. She crawled underneath the rear end so that she could hook up the power wire to the mega fuses.

The power wire connects to the front of the buss bar (at the top of this picture). This is looking up from below.

The wire is secured with an adel clamp just in front of the mega fuses and then follows the forward battery box support to the right side of the battery box.

There, it drops down and hooks to the right side of the inRESERVE solenoid.

I installed the power wires in the rear load cell that will connect to the mega fuses. I left them a little long for right now until I have a better idea where all the wires will route in this area.

I also installed the power wires in the front load cell and snaked them down through the transmission tunnel.

The run along the upper left side of the transmission tunnel…

…where they follow the left parking brake cable back to the mega fuses. These are also left long for now.

Jenn then installed the inDASH MAX box on the aft side of the firewall.

It’s installed just to the left of the mastercell.

Finished Passenger Seat and Electrical System Components

I wrapped up the passenger seat by trimming the bolts and installing the wire that connects the mechanisms on the two tracks.

I then cut some pieces of 1/2″ steel tubing and welded them into the chassis then ground them flat.

I finally determined the location for the master cell (left) and front load cell (right). The load cell will actually install on the other side of the firewall, but I’m drilling it on this side because I don’t have drill access on the other side.

After deburring the holes, I temporarily bolted the mastercell to the aft side of the firewall.

The front load cell is mounted on the right side of the firewall. This should keep it clear of the throttle mechanism on the left side and allow easy access if I ever need to access it.

I’ve been playing with the location of the heater assembly. This is quite a bit bigger than the one Factory Five sells, so it can’t install on the firewall. I think I’m going to end up installing it at an angle as shown and then run a pair of 3″ diameter pieces of ducting from the heater to the firewall. A plenum on the other side will distribute the air to the foot boxes and defroster vents.

The ducting will connect to the plenum through this pair of 3″ diameter holes. There will be flanges installed to the firewall here.

Coolant Reservoir Plumbing and Began Electrical System

I routed the silicone tubing from the water neck to the bottom of the coolant reservoir. I used some zip ties and plastic tubing to secure it to the upper radiator tubing. I’m not sure I like this method of securing the tubing, but it will do for now.

After a two month wait, we finally got our electrical system from InfinityBox. We ordered the two-cell system which includes a master cell under the dash and two load cells, one for the front of the car and one for the rear. There’s plenty of room under the hood for the front cell, but there’s really very little room in the rear of the car. The trunk has two levels: Under the rear (lower) level resides the fuel tank. Under the forward (upper) level resides the differential, driveshafts, suspension (including remote reservoirs), parking brake cables, rigid brake lines, battery, inReserve system, rear load cell and mega fuses. The other consideration is that all of this needs to maintained from below once the car is assembled.  Although there is plenty of volume above the differential, it’s virtually impossible to reach from below. All of the electrical components really need to be installed between the differential and the fuel tank. The battery takes up the bulk of that space, the but the side of the battery box is a pretty convenient spot to mount components.

The right side of the battery box has the inReserve system and primary mega-fuse, but the left side of the box is a perfect place for the rear load cell. This keeps it well protected, but easy to access from below. This is currently attached with bolts and nuts, but I’ll replace the nuts with nutplates to make this easy to remove from below in case I ever have to do so.

The InfinityBox instructions recommend that the primary power wire from the battery to the mega fuses be as short as possible. That means that these need to be installed in the rear of the car as well. I spent some time playing with various mounting locations and settled on installing them high on the left side of the car. I fabricated a small steel plate and welded it to the chassis and installed 8 riv-nuts.

The mega fuses install from below so that they can be accessed in the future if necessary. This will hang over the top of the fuel tank slightly, but there should be plenty of vertical clearance to access these with the tank in place.

InfinityBox inRESERVE Installation

I’ve been contemplating where to mount the InfinityBox inRESERVE components and finally settled on the right side of the battery box. This will provide a short run from the battery positive terminal to the 350A mega fuse (since that is an unprotected wire).

I decided to put the fuse below the latching solenoid to avoid a super-tight bend in the cable from the battery to the fuse. There is a jumper from the other side of the fuse to the side of the latching solenoid.

I cut a 2.25″ long piece of the 2/0 wire and crimped terminals on the ends with the appropriate clocking to mate to the terminals.

I then installed a piece of the heavy-duty heat shrink tubing over the whole assembly. This is essentially rigid now.

Finally, I slipped a couple of boots over the terminals.

After reinstalling the jumper, I drilled and bolted the components to the side of the battery box with some short 1/4-20″ bolts.

While I had the battery box out, I drilled out the holes that pass the battery cables and installed larger rubber grommets. Now the wires can be installed without removing the grommets.

I reinstalled the battery box (hopefully for the last time before final reassembly) and then fabricated and installed the positive battery cable. As you can see, there is a nice, gentle bend from where the cable comes out of the forward side of the battery box to the right side of the mega fuse and there is no way for this cable to contact any other structure in the car.

Inside the battery box, the battery positive cable makes a fairly sharp bend to turn toward the positive terminal. Just like the negative terminal, there is a right-angle terminal on the positive wire, but there is also a right angle protective boot to prevent any contact with the cover plate. I reinstalled the negative cable but will leave it disconnected for now.

You can also see in this picture that I’m temporarily using screws to attach the battery box to the chassis. The heads of these screws are too tall to allow the battery to be installed with all of them in place, so I only installed the aft screw (at the bottom of the picture) and then put in a handful of screws on the forward side of the box for now. After final reassembly, I’ll rivet the box in place and the rivet heads should not interfere with battery installation and removal.

Battery Ground Cable

The black heat shrink tubing showed up today, so I crimped on the battery terminal and applied heat shrink tubing to each end.

I reinstalled the ground cable and hooked it up to the battery. The cable has to make a pretty sharp turn to exit the box, so I may reverse the cables or make a different exit hole.

Ordered InfinityBox

I’ve been working on our electrical system configuration for weeks now and we’re finally happy with the plan. We’re installing the following items from InfinityBox:

  • InfinityWire 20-circuit Wiring Harness

  • inDASH MAX Dash Lighting Module

  • inLINK RF Control Module

  • inRESERVE Active Battery Monitoring

This will let us control the following electrical circuits in the car:

Front

  • High-beam headlights
  • Low-beam headlights
  • Parking lights
  • Turn signals
  • Hazard lights
  • Ignition
  • Starter
  • Heater
  • Horn
  • Radiator fan
  • Electric Power Steering

Back

  • Brake lights
  • Parking lights
  • Turn signals
  • Hazard lights
  • Seat heaters
  • Stereo
  • Interior lights
  • Trunk light
  • inRESERVE solenoid

Positive Cable Termination

I purchased some 1.1″ heavy-duty heat-shrink with adhesive for the battery cable connections. After shrinking, this stuff is pretty thick and very tough. Most heat-shrink tubing is more like a rubber sleeve, but this is closer to rigid plastic, so it should provide outstanding strain relief for these terminals.

I then slipped a rubber boot over the end. All power leads will have boots for protection.

This was a pain in the ass to slip over the super-thick heat shrink tubing, but it should work fine.

Ordered Switches

We ordered our switches tonight from Billet Automotive Buttons in Australia. Samples are shown below. They have four sizes of buttons (16mm, 19mm, 22mm, and 28mm) in both black and stainless and can be custom laser etched with any text or graphics you want. All of our switches will be 22mm, momentary stainless with logos on the button and no text around the edge. We ordered switches with the following logos:

  • Low-beam headlight with blue ring
  • High-beam headlight with blue ring
  • Parking lights with orange ring
  • Hazard lights with red ring
  • Fan with green ring
  • Interior lights with white ring
  • Stereo with green ring
  • One surprise button we’ll reveal later 🙂

We also ordered the following 14mm indicators:

  • High-beam indicator with blue light
  • Left and right turn signal arrows with green lights

I also ordered a single 16mm red light with the word “ALARM” laser etched around the edge.

Primary Power Wires

I cleaned off a section of the chassis and ground off the plating from a 5/16″ bolt and clamped it in place.

I welded around the bolt head to create a grounding stud for the battery.

I’m using 2/0 welding cable for the starter and ground cables. I crimped a connector on the end and temporarily routed it to make sure it won’t hit anything. I’ll add some heavy duty heat-shrink tubing over the joint when it arrives.

I temporarily routed the battery positive cable from the right side of the battery box down to the lower right side of the tunnel.

It snakes over the 4″ round cross tube…

…and up the diagonal on the right side of the transmission.

It then drops down the diagonal to the right of the bellhousing and will loop back to the starter. I’m not 100% sure I like this routing. The other option is near the top of the transmission tunnel, but I want to stay away from the parking brake cables and I’d like to keep it separate from the other electrical wires.