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Member Since 23 Jun 2010
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#471854 "taking Oval To Blue Horizon" Lenny's Build Thread 2010-2015

Posted by Lenny on 31 March 2015 - 08:14 PM

Looking sweet mate. You've done a stellar job in making everything look great, your attention to detail is very impressive!

 Thanks very much David, much appreciated.  

It's Alive! Cue bass rumble.
Did you get the whole thing with the head unit working?

Not yet,
:lol: I've gotta take out headunit to check connections,
Reluctant to do this fast, as its a pain to get back in due to limited space at rear,
Ill sort it out perhaps Friday when I'm not working.

#471782 "taking Oval To Blue Horizon" Lenny's Build Thread 2010-2015

Posted by Lenny on 31 March 2015 - 05:07 PM

Progress update:
Crimped the final connections this morning.


Battery cover refitted:


Capacitor and amps now live:



Sounds great from default settings,
I attempted self calibration and it alerted me that the rear drivers side speaker is not working :rolleyes:

"Pain in the glass" as they say in Holland,
Well I've successfully narrowed it down to the RCA connection at the rear of the headunit,
It must have become loose or disconnected as Channel 4 on the amp isn't receiving a signal from the headunit.

Once i solve this,
I can then calibrate the system.
At this point just want the process to flow like water lol heads wrecked and I can't leave it alone :lol:

#471326 "taking Oval To Blue Horizon" Lenny's Build Thread 2010-2015

Posted by Lenny on 30 March 2015 - 12:34 PM

Looking good there buddy and looking forward to the future updates. You seem to be having a ball  :)

Was fun mate but now i just want it to be over lol

Today fitted some decals:



Then brought the old battery in to the kitchen table and wired it up to the capacitor for first charge lol


Despite being red cable,
Thats negative feed wired from battery to cap,

The positive must be connected via this resistor until the cap has 8 volts in it.


So here we have capacitor held in right hand,
Voltage metre probe held in my teeth,
And resistor held in pliers with my left hand yes connecting to a car battery,


The chair has wooden legs so should be ok :lol:


Got up to 8 volts


Then connected full cables to battery,
Brought it up to 12.4


Now fitted to the car awaiting the final crimp connections tomorrow,

I've completed wiring of the tv tuner but i think I'm going to need to wire it directly to the battery because the start up screen and menu connection transmitting to the headunit is all fuzzy,
Think I'm out of my league with the TV tuner and flip down screen.

I've still gotta fit team hecko wind deflectors and short stem aerial but at present i need a break from working with the car lol starting to wreck my head.

Gauging interest on factory speakers before i throw them out if anyone wants to pay shipping.
Excellent condition 25W speakers,
Going in bin next sunday if no interest.


#471118 "taking Oval To Blue Horizon" Lenny's Build Thread 2010-2015

Posted by Lenny on 29 March 2015 - 08:27 PM

Todays progress:

Well its day three of flat out working on the car,

Started off with the TV Tuner


Wired up a loom for it,



I then routed the cable from the passenger fuse board area back along factory loom to the passenger side boot panel where i plan to mount the tuner box.



I then had to temporarily cease installation of the tuner as i require a ring crimp terminal to earth a cable aswell as some more insulated female crimps,
I didn't fit aerials yet neither as the manual says the tuner will display signal levels to assist mounting in optimum location,
So I've gotta get it powered up first,

I then got the Ford IsoFix bracket fitted for the little man,

Hoovered out the car and put the whole interior back in except for glove box,
Not one screw or clip missing,
Very surprised at that lol

I then routed both 4 Gauge cables from the amps through the firewall,


Fitted the 30 and 40amp circuit breakers, bolted to the side of the battery box all ready for final crimp ring terminal to be applied.



I've got the crimps,
But i don't have a large crimper,
I've gotten a loan of one from maintenance workshop in work before to crimp all other connections,

I've now got the final four connections ready for crimping,
Should have these done on Tuesday morning and that will see the amps fully functioning,

Ill pick up crimp ring terminal tomorrow and get back to installing the TV Tuner,

I've decided to source a company to install the flip down Monitor as i don't trust myself to line it up correctly,
I've got all the cables figured out etc.
Just need a company to fit it in there for me,
Ill look in to it in coming weeks,
Its been a fun three days but im glad to be at the end of it because its quite stressful aswell as enjoyable trying to make everything go the way you want it to and always planning whats to be done next, in a bid to maximise daylight time,
Aswell as reserving some inside jobs for times that it begins to lash rain lol

Looking forward to getting back to work in order to obtain the crimper :)

#470795 "taking Oval To Blue Horizon" Lenny's Build Thread 2010-2015

Posted by Lenny on 28 March 2015 - 09:43 PM

Been at the car today from 9am to 19:00
Had to drive with only drivers seat installed to local DIY store lol
Bit faster with no interior, had to purchase some more bolts as previously mentioned,
Got home and fitted front speakers completly.

I failed to take many pictures,
Fitted front speakers and wired in the feeds from amp to speakers aswell as the front audio to boot connector feed.

Removed the iso adaptor loom and hard wired all cables to reduce bulk at the rear of the headunit,
Would have been tight if not impossible to fit the headunit back in along with the additional 7 RCA plugs.

Took some time and Haynes manual




Front speakers now fully installed and door cards fitted,

Tomorrow I've gotta fit the isofix bracket in back seat,
Refit all panels,
Route power feeds through firewall to battery,
Fit PlayStation socket extensions,
Begin wiring Xtrons HD DVB Tuner.

There was a lot of time spent phishing RCA's in to headunit cage today guys,
Had to go in one at a time and took forever,
Was like seeing your child being born,
The euphoric feeling when the RCA cable finely peeps through where you want it :lol:
Headunit now refitted and functioning 100%
Currenly powering front speakers from headunit via the new plug&socket system in the boot compartment until th3 amp power is complete.
More progress tomorrow thanks for reading.

#470528 "taking Oval To Blue Horizon" Lenny's Build Thread 2010-2015

Posted by Lenny on 27 March 2015 - 10:43 PM

Tweeters now fitted in stock locations.

I did try dissecting the tweeters to smaller size as in removing there grill but not a chance,
These are sealed tight one inch silk.



Progress continues at 7am :)

#470524 "taking Oval To Blue Horizon" Lenny's Build Thread 2010-2015

Posted by Lenny on 27 March 2015 - 10:33 PM

Absofreakinglutely awesome! Love it when a plan comes together. Keep up the work as I can't wait to see the final results.
I am very surprised how I couldn't see much/any sound deadening on the metal floors used. Only the thick carpet to cut noise intruding the cabin. After driving in a Lexus and an Opel Insignia recently, the sound deadening levels in those cars were much better than the Ford. That's one thing that I would really like in my car as on the motorways, the noise can get tiresome. 

 Thanks mate,
Id say the mondeo would have more sound proofing aswell,
I did notice an increase in motorway noise after fitting the bigger wheels bit it doesnt bother me much,
Im concerned about putting too much weight in to the car, so im sort of holding back on the sound proofing to see how much effect the rest of the items have on driving.

I will be stripping out the floor again because ive found my focus has another common fault :rolleyes:
Paasenger footwell wheel arch weld hickup,
This has happend on production line where the machine stoped welding for a second causing a gap in the wheel arch joint allowing water in,

I had assumed it was pollen filter housing, but since seeing it today i know now its wheel arch,
Lad on RS owners club Ireland had same problem and told me about it a while back.

Also im tempted to fit roof monitor tomorrow but afraid ill make a balls of it lol

Lenny you are a legend man. I can't believe you've basically stripped your car back to bare metal I wouldn't have the patience. Can't wait to see the end result. 

Thanks very much Phil i was just short of rubbing my nipples while stripping the car today mate :lol: i was giggling with excitement while carrying parts in to the house.

The drivers seat is easily 40kg with airbags in it,
Good modification would be a set of aftermarket bucket seats lol

Lenny dont wanna alarm you mate but someones nicked the seats outa your focus :o

i thought there was an increase in leg room :lol:

#470460 "taking Oval To Blue Horizon" Lenny's Build Thread 2010-2015

Posted by Lenny on 27 March 2015 - 07:37 PM

Darkness is beginning so I've had to stop on the car,
No difficulty's today at all except for my miscalculation on quantity of M6 bolts purchased this morning.
As result I've gotta go back to DIY store tomorrow for another six.

Ive run the power feeds for the amps down the passenger side of the car along side the factory fitted loom underneath the carpet,

Then run all audio speaker feeds down the drivers side along side factory loom under the carpet.

Since I'm not installing door poppers i had no need to route cables through to the doors,
Instead i used the Haynes manual to diagnose the correct factory loom cables and spliced in to those cutting off the feeds from the headunit,

Rear passenger side left speaker:


Rear Drivers side right speaker:



Audio is now fed from the headunit via RCA cable to the amp,
Then out of the amp to the speaker via these cables.

The rear speakers are now fully installed,

I've run the front speaker feeds
Front speaker output from headunit
To the rear of the headunit along with the remote line feed and three RCA's

I plan to cut the front speaker feeds at rear of headunit wiring both ends up to relevant looms.

I've drilled out the front speakers and currently in the process of fitting the replacement brackets this is where I've run out of bolts.

I've had to put seats back in,
In order to reconnect battery without an airbag error,
Then locked it up for the night.

I've brought in the front door tweeter housings,
Going to try sort them out inside tonight,

Here's some pictures i took at random times of the day guys:






#470311 "taking Oval To Blue Horizon" Lenny's Build Thread 2010-2015

Posted by Lenny on 27 March 2015 - 12:24 PM

Were in progress:






#470073 "taking Oval To Blue Horizon" Lenny's Build Thread 2010-2015

Posted by Lenny on 26 March 2015 - 06:03 PM

Fitted speaker Grill


Fitted the buggy


Went to Halfords,
Actually met a very helpful staff member whom assisted my purchase,
Took out his own Torx set and tried the various sizes on the focus so i needed T40 and T50 Torx bits

So i purchased individual T40 & T50 Torx drive sockets and the Allen key style set.


I then went to local Engineering supplies shop to purchase rivets and male spade connectors,

Then at 11:00am on route home to perform a days work on the car,
Victoria had alternative plans entailing two trips to two different doctors and a trip to the hospital which all ended in the same diagnosis of Tadhg's getting teeth.

Had an unmanned, unofficial ford meet at the hospital car park:


Consumed my whole day,
Sadly no further progress can be done as I've gotta try sleep now as I'm in work again at 23:00

I will try get somthing done in the morning after work,
Perhaps if i leave a bus fare on the table :lol:

Tried the rivets and no good,
The brackets are too thick,
Ill try get some M6 nut & bolts tomorrow to secure brackets instead,
Perhaps camp outside DIY store after work to ensure i get them before going home to the chaos.

#469886 Clarkson In Trouble Again - RIP Top Gear

Posted by Lenny on 26 March 2015 - 09:03 AM

What are the odds the show carries on, but the Stig suddenly puts on a bit of extra weight as well as shouting 'WANT MORE POWER' a lot?
New Stig's lap times might go down the pan too ;)

Maybe start a thread for TopGear merchandise

This is my stig passport photo holder lmao


#469877 "taking Oval To Blue Horizon" Lenny's Build Thread 2010-2015

Posted by Lenny on 26 March 2015 - 08:19 AM

I've run my power cables inside the trim under under the seal that runs around the passenger doors! :)
The Torx bit you Will need will be around a 50.
As for Clarkson... Gutting.. but to be honest.. imagine Guy Martin in His place!


Looking good there Lenny. It's all coming along nicely. I like how all the amps are on one side.
With regards to your wires, I put my 4 awg wires under the side sill on the left of the car. I just tucked them on the inside after going from behind the glovebox. I had to take out the glovebox to make that work. 
Sadly can't help you out with rivets :(
As for the torx, let me know when you find out as it's something I too want to know.
Best of luck with the upgrade. 
Gutted about Top Gear but still Clarkson should not punch other people. 

Morning update:
Had a sesrch on google says the Torx is a T50
Going to halfords after the school run to pick up a T50 torx

I can then earth the cable in back seat,
Fit the isofix braclet
And remove all seats aswell as carpet to route both power cables through the factory channel in the floor.

Ill also bring rear speaker bracket and drop in to B&Q for advise on rivets.

Meanwhile the car has loom hanging out everywhere its like an indian Taxi full of dream catchers and beads

#469695 Clarkson In Trouble Again - RIP Top Gear

Posted by Lenny on 25 March 2015 - 07:47 PM

I saw a clip on YouTube of James may and he said we come as a package and how top gear will continue but didn't actually say he's walking away but I certainly got that impression.

In my opinion TopGear was Jeremy Clarkson,
Those guys played a part but back in 90's it was Jeremy Clarkson theres no show without him,
The guys just dont have his natural tallent and way with words,
Im genuinly gutted to hear todays news,

Can imagine getting in to taxi some night and ow Jeremy is this your new job then ?

#469676 "taking Oval To Blue Horizon" Lenny's Build Thread 2010-2015

Posted by Lenny on 25 March 2015 - 07:21 PM

Id appreciate your input on this guys im not 100% happy with having routed both 4 awg power cables across the roof lining
How have you routed yours?

Also can anyone advise me on rivets,
I've bought a pop riveter,
But need rivets,
The drill bit i used to remove old rivets was 5.5mm
I assume i need M6 rivets but the need to be long aswell rite?

Also Torx,
What size Torx is required to remove seat bolts as i need to clamp an earth ring in to one of the back seat bolts.

And finally poor Jeremy Clarkson, Gutted to hear the news :(


#469406 "taking Oval To Blue Horizon" Lenny's Build Thread 2010-2015

Posted by Lenny on 25 March 2015 - 07:12 AM

Im off work tonite,
Booked it off as holiday, not due back in until 23:00 tomorrow night,
So im going to install the speakers and route cables for the amps,

Bit of a change on the build plan aswell,
Ive decided not to fit door poppers to rear doors because the NCT can fail it under the terms that its modifying the original design and safety officals wouldnt be able to open the door in the event of an accident,
Last thing i want is to have to change rear doors for NCT lol

Second thing is;
Ill only be sound deadening the roof and doors next month,
Going to leave the main area untouched for the moment to see how much difference in weight the rest of the items have,
Before i add anymore.

Today im starting with routing of amp power cables,
Followed by removing headunit to plug in RCA's and Remote feed.
Then moving on to upgrading rear door speakers

Unfortunitly the amps wont be functioning until most likely next week,
Because ive got four crimp connections left to complete,
This being 4AWG cable i need a large crimp tool,
I obtained a loan of one from the maintenance worshop in work before and i can do again but those guys only work 8-8 ill see them on monday and crimp final connections tuesday morning.

Not in a position to install TV tuner or Flip down screen yet as i dont currently have the sound deadening to apply to the roof and i dont see point i removing everything twice.
Im also awaiting arrival of an RCA splitter from China to complete connections.

Ill edit this post with progress when darkness falls today im going to make hay while the sun shines.

Converted one set of the JL C3 650 to Coaxial form for the rear doors,
These are pretty heavy lol
Still use the crossover box when in coaxial form.

Left is Coaxial form,
Right is Component form,



Centre cone twists to unlock revealing spade terminals to fit the Tweeter:


The Tweeter cone clips in to support tweeter in centre of speaker


Seems a shame to hide these inside door


Crossover box's have six configuration options,
Will take some playing to get these setup correctly maybe low setting in front and high in the back.



Its Gonna Bounce!!

Edit: todays progress

Lovely rain has put a short end to progress today,

Heres some pictures ill post details of faults found in the next post,

Started off very well,
Run all power cables to the mono amp still need to crimp two earths and charge capacitor,

Found a threaded M6 hole in the boot so obtained an M6 bolt and earthed the cables was epic lol




Cut out some holes and fitted grommets for cables in panel above mono amp



Fitted all cables to the mono amp and capacitor,


Routed FlatBass cable to opposite side of the boot for the sub and attached banana plugs


I've routed all three RCA cables from the boot up the drivers side of the roof lining,


Tried to route both 4AWG power cables along the floor of passenger side under the doors from boot to glovebox but there wasn't enough space,

So i alternatively routed both power cables up along the passenger side roof lining down pillar in to passenger footwell,


Took off rear passenger door, drilled out rivets removed the 25W stock speaker,


Fitted the JL C3 650 then discovered i don't have the correct size of rivets to fit it,

Here's how the boot compartment is looking now, its complete except for the two earth feed crimps, those cables will be hidden once crimped.