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Cyber T Returns Part 5

We Hold Painless Performance to Their Name Claim: Is it Really Painless? Part 1
By Chris Shelton
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Open space is at a serious... 
   
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Open space is at a serious premium in a T-bucket, but our man and Tech Center wrench Jason Scudellari found an open spot on the passenger side of the fuel tank. He summarily made an aluminum plate to the panel's dimensions and glued the panel to the bed walls with epoxy.
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Jason also installed a multiple... 
   
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Jason also installed a multiple contact terminal strip to the fuse panel's plate. The pronged strip in Dennis' hand "commons" the strip so that all of the terminals provide the same function.
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In this case, that function... 
   
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In this case, that function is grounding. Now all fiberglass-mounted components' grounding wires (taillights, gauges, switches) route to this strip instead of spreading willy-nilly about the car. The fat wire in Dennis' hand connects the strip to the chassis.
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Jason mounted the Total Performance-supplied... 
   
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Jason mounted the Total Performance-supplied Vintique taillights while Dennis installed the grounding kit. He removed the stainless bezels and glass lenses from the assemblies, masked the panel where we thought the taillights should go, and scribed the masked area.
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Jason cut the area free with... 
   
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Jason cut the area free with a saber saw and fine-tuned the holes with a die grinder.
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Dennis then routed the taillight... 
   
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Dennis then routed the taillight and fuel level sender lights through adhesive-backed cable tie clips and to the individual components.
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There's a good chance that... 
   
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There's a good chance that we'll either remove the body for later stories or change the bucket's taillights at one point, so we wired the taillights with insulated bullet connectors.
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We installed the tank for... 
   
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We installed the tank for the next step and discovered that our '39 Ford taillights' buckets ran smack-dab into the fuel tank; they're too deep. The bucket doesn't need to be that deep, so Jason suggested cutting the bucket. We found universal taillight sockets at the local parts house and measured the flange's diameter. Jason then cut the buckets down so the sockets' flanges would just fit.
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Jason then shimmed the fuel... 
   
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Jason then shimmed the fuel tank about an inch forward with a section of tubing between the frame and rearmost tank bracket. He also relocated the outboard mounts inboard because they interfere with the coilover brackets at the tank's new location.
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These changes don't come without... 
   
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These changes don't come without consequences. The Watts-link pivot bolt now comes perilously close to the fuel tank at full suspension compression. We'll remedy that by using a button-head bolt in lieu of the taller hex-head bolt.
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The modified buckets now fit...barely.... 
   
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The modified buckets now fit...barely. It's a clever fix, but if we had to do it over, we'd rethink our taillight locations.
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Jason reinstalled the tank... 
   
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Jason reinstalled the tank and finished up the back forty with the Auto Meter-supplied universal tank sender. It fits tanks that fall between 5 and 24 inches deep. Simply measure the tank's depth, reference the figure on the supplied instructions, and shorten the float stalk and the sender's flat stem to the instructions' provided scale.
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We made the rest of the install... 
   
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We made the rest of the install easier by removing the fuel tank. The harness's wires sprout off the panel and go to their attendant locations in groups, so Dennis separated and tape-wrapped the wiring groups into neatly taped bundles.
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Total Performance drilled... 
   
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Total Performance drilled our interior kit's molded seat base for the wiring harness, so Jason fed a fish tape through the seat base from the cockpit to the bed.
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Dennis taped the forward-running... 
   
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Dennis taped the forward-running wiring bundle to the fish tape and Jason pulled it through the car.
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Dennis finished off the rear... 
   
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Dennis finished off the rear wiring with split-loom shield after Jason fished the bundle through.
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Jason routed the wiring bundle... 
   
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Jason routed the wiring bundle through the cab and secured it with screw-mount saddle clamps. That will relieve the bundle's strain and keep the wiring where it's supposed to stay: under the carpet.
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The bundle that Jason pulled... 
   
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The bundle that Jason pulled through terminates to several places: one to the dash (gauges and switches), a second to the starter and the battery (main lead), and the third to the driver's side framerail. Jason pulled the dash bundle through the speedometer hole and pushed the other two bundles through the Total Performance-drilled floor holes.
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The Painless Performance kit... 
   
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The Painless Performance kit includes a parts store-available Maxi fuse and holder in lieu of a troublesome fusible link.
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Jason glued a 1x3 pine strip... 
   
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Jason glued a 1x3 pine strip to the firewall's backside and screwed to it the Maxi fuse holder. Bare in mind: we realized that the pine strip interfered with the throttle pedal's location. If we did it again, we'd mount the strip towards the passenger side more.
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We made the pine strip longer... 
   
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We made the pine strip longer than the Maxi fuse holder so we could mount another grounding strip and a rubber-coated line clamp to loom the wire bundle in. Dennis terminated a 10-gauge wire with a ring terminal and bundled it with the loom.
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Jason then routed 10-gauge... 
   
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Jason then routed 10-gauge wire from the starter solenoid up through the floor and ultimately to the Maxi fuse. The fused end of the Maxi fuse will eventually lead two places: one wire feeds the fuse block via a wire incorporated in the main harness and the second wire feeds the ignition switch.
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The harness includes one common... 
   
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The harness includes one common wire for gauge power. Jason piggybacked that lead with another wire and a spade terminal.
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Jason plugged that piggybacked... 
   
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Jason plugged that piggybacked terminal into the tachometer and pulled the piggybacked wire back through the gauge hole. He piggybacked a second wire that ultimately goes to the headlight switch and a third wire that will go to the ground strip. Those two wires also route back through the speedometer hole.
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The three wires that Jason... 
   
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The three wires that Jason piggybacked off of the tachometer (hot, ground, light) route to the next available gauge. Jason piggybacked those wires from the second gauge to the third, fourth, and fifth gauges in the same manner. He wired the speedometer's power feed with a wire of its own to reduce interference risk.
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Remember the Maxi fuse's open... 
   
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Remember the Maxi fuse's open terminal a few steps back? Jason routed another 10-gauge wire from it to the ignition switch. The ignition switch disperses power to two places: the starter solenoid (purple wire) and ignition coil.
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Jason also mounted the high... 
   
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Jason also mounted the high beam indicator with the supplied wiring and warning light. Even with the gauges, we're a sucker for oil pressure warning lamps (idiot lamps? Who you calling idiot?), so Jason pulled power from the main gauge power feed. He routed that power to the lamp's input side and routed the grounding side to a second (parts store) oil pressure switch.

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