Samurai rescue project UPDATED!

[twiss]

I had a load of annoying problems with my rear lights. Mine are spanish and have an earth bar running across the back.
It went rusty and after several attempts at fixing them, I binned them and went for forklift lights

[Christoff]

Sounds annoying could do with fixing these really. To replace the light I'l have to chop the wiring out and solder in a new one. I might put connectors in or something.

[ScottieJ]

all my rear light earths have been joined to one single earth, however they have also been moved into the tailgate and the loom has been cut, extended and ran through the cab instead of underneath.

[Christoff]

ok nice idea. So if i cut out the lights and resolder some new wires with a new route in the cab they should last and be easy to maintain.

Having the single earth makes things much easier as well. I will still need a new light though as the connection is corroded off the back of one of the bulbs. If i cant solder it back together that is

[Tramp]

you will have trouble soldering the cables, mine were correded (with black corrrosion on the cores) which made them impossible to solder - its all about cleanliness isn't it? for me a few lugs/cables came off the terminals on the back of the bulb holders, I cut off as much residue as I could with a Stanley (on the back of the lights) then flatted it with emery, I then soldered a bit of new (it had to be new because the old was corroded and unsolderable) cable on, then I crimped the new cable to the old using 'through' crimps and sealed the joint using self amalgamating tape, I also sealed the back of the light where the terminals are with the same self amalgamating tape (you can see the terminals are recessed in circle of plastic)

[Christoff]

Day two progress

Front part of OSR arch looks a mess, not sure how this will be tackled


I can see right down into the channel of the sill, good news is that the rot only seems to be on the outer skin of the sill, looks ok in there but im expecting to find more rot in there later. Everything is caked in sand/silt and i cant wait to have it all chopped off and cleaned up. Need to buy plenty of waxoyl or cavity wax for in these spaces


Rot around back of floorpan


Rest of floorpan looks good


Bulkhead is good as far as i can see

[Christoff]

The wiring problems

MOst of the pictures were taken for my own reference really but it shows what a poor design the wiring is, I would like to remove the whole lot and re-loom everything making one single earth point and routing the wiring better







NSR light cluster


Broken earth connection on OSR light. Tramp I didnt think the back of the bulb holder would take soldering in this condition but its worth a try i guess. Only one wire is broken so maybe i can do something if i can make a sound connection.


One of these earth point screws needs to be grinded off bacause its siezed in and rounded off




Lastly can anybody tell me what this is, theres a long section of wire coming off the loom eith a large black box on the end that says FLASHER on it

[Christoff]

List of jobs so far

-Order a new OSR lower corner section of body £29+vat
-Grind off the last earth point at OSR
-Resolder/repair broken wire on light cluster
-Tidy up all wiring
-Repaint tow bar bracket and number plate plynth
-All welding work is not been done by me so a friend of mine is taking care of that
-Buy lots of hammerite black / cavity wax / underseal / stone chip ...everything
-find a new set of mud flaps

[dan_2k_uk]

I have tried to repair that same problem a few times on my lights. It can be done but mine just kept going wrong. Im ditching my lights so I might have one spare. I cant remember which side was faulty.

Looks like you've got a bit of work to do there.

Dan

[Christoff]

Anyone got these parts;

Fuel tank skid plate
Drivers rear mud flap

ta