Saturday, December 14, 2019

Relocating ignition coils from valve covers to front inner fenders.

Before
After


Box to house coils




Four coils per box

Raised front of car and removed front wheels for ease of access. Re-purposed 3 foot fluorescent work light adds plenty of light. 

Area selected to mount coil boxes, inside rear of fenders. One on drivers side and one on passenger side.


Supporting coil box in place to fabricate and fit mounting brackets.





Diagonal bend of a bracket. 


Fitting brackets before welding


Brackets welded to boxes.




Bolted in place using existing running board and fender mount fastener locations 




Holes drilled for spark plug wires (two wires per hole)


Plastic tubing will guard wires from chafing 


Removing coil/injector wiring harness





Engine with harness and coils removed. There was also a harness for spark plug wires crossing over the engine I removed. 

Coil/injector harness laid out on the table. 

Each connector was labeled to identify corresponding cylinder

Dissecting the harness to extend the coil wires 


Notching coil boxes for coil wire passage






Building spark plug wires

Lubricating spark plug boots in dish soap and water to ease assembly

3/8 steel tubing used to slip spark plug wire through the boot




Stripping the spark plug wire one inch to add connector end



Crimping end on wire


Wood dowel with shrink tubing to serve as a depth gauge to set wire in boot. Boot depth is critical on HEMI engines for moisture seal purposes.

Black end of dowel inserted in wire connector, then wire is pulled through the boot until end of boot aligns with beginning of white shrink tubing






Routing spark plug wires to the coil boxes

Store bought wire separators, home made stand-offs







Installing coil ends on spark plug wires. Two styles were needed for each coil, one late model GM snap on type and one early push in.


I pulled the wires through the protective tubing then through the holes in the box. I then trimmed the wire to fit into the coils to assure the length was good before installing the boots and connectors


I used the same 3/8 steel tube technique to slip the spark plug wire through the coil boot as I did with the Spark plug boot but with a shorter piece of tube 

When the spark plug boots and connectors were all installed I connected the coil wires and the wiring was done
I labeled the box covers and made rubber gaskets for them






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