V1 ccgillett's Track Goblin - '08 SS/TC

[Desert Sasqwatch]

The center bolt should hold everything in place, regardless if you have the plastic clips or not. Just need to make certain the plugs are fully seated and not depend upon the center bolt to pull everything as tight as it should be. Having the fusebox separated would probably facilitate this better trying to see the plug interfaces for being flush and tight.

 

[Traé]

I figured this out, but now I have a bigger mystery. In my previous post I was whining about the plugs not clicking into place and the wires being in the way. I was tired when I wrote this, my realization today is that the bottoms of several multiplugs (the part that "clicks into" the fusebox base) are missing. Here it is in pictures:

First, here's the bottom of a multiplug (the term Lonny uses in the assembly videos). There's a plastic tab in the fusebox holder into which this clips, super easy:

View attachment 45972

Here's a couple of the plugs missing their bottoms, no way these can clip to anything:
View attachment 45973View attachment 45974

I've tried searching for "multiplugs", "fuse box plugs", "fuse box connector plugs", etc. and I'm coming up empty. Does anybody know what the correct technical term for these parts are? I found one of the "bases" (for the small rectangular one at the far end of the box) in the donor parts I received when I bought the kit. The other two plugs, show above, have no bases and I need to order some or go to a junkyard.

Anybody have any insight into part names, numbers, etc.?

It occurs to me that I could simply bolt these plugs to the fusebox itself, and then drop the whole thing into the fusebox holder, there is no electrical connectivity between the holder the the fusebox itself. But I'm not convinced that's the best idea.

I can’t find part numbers for those plugs either. I’d say a pick and pull is your best bet.

 

[Robinjo]

Do you have an LKQ or other pull your own parts yard? I’d just go there and pull them. I believe these are pretty universal to Cobalts, not just SS versions.
You can also just bolt them to the bottom of the fuse block but that may make it harder to secure the block into the plastic base. Maybe not if you don’t have the connector covers.

 

[Sluggonaut]

Anybody have any insight into part names, numbers, etc.?

It occurs to me that I could simply bolt these plugs to the fusebox itself, and then drop the whole thing into the fusebox holder, there is no electrical connectivity between the holder the the fusebox itself. But I'm not convinced that's the best idea.

I ran into this problem too (trying to find connector part numbers) and the only thing I could find was eBay listings for fuseboxes or various plugs. More often than not it was an entire fusebox assembly and you are paying way too much for the actual parts you need (example).

I had one of the captured bolts strip out on one of my connectors, so I used a separate nut and bolt to attach that plug to the fusebox. It makes it a little harder to get the fusebox with one plug attached to slide easily over the others that are snapped into the holder, but with some patience, it goes together just fine. I think bolting the ones in question to the fusebox is the way to go and see if it is acceptable.

 

[ccgillett]

I ran into this problem too (trying to find connector part numbers) and the only thing I could find was eBay listings for fuseboxes or various plugs. More often than not it was an entire fusebox assembly and you are paying way too much for the actual parts you need (example).

I had one of the captured bolts strip out on one of my connectors, so I used a separate nut and bolt to attach that plug to the fusebox. It makes it a little harder to get the fusebox with one plug attached to slide easily over the others that are snapped into the holder, but with some patience, it goes together just fine. I think bolting the ones in question to the fusebox is the way to go and see if it is acceptable.

Yeah, I really don't want to pay $109 for a what is probably $5 in plastic pieces...I'll only go that route if/when I blow something up getting this thing fully wired :-D .

I'll lay it all out tonight and see if I can't get the plugs inserted cleaning into the fusebox. I did check around with a few yards in my area and none of them have any Cobalts laying around. Looking at the broader world of GM parts I think those plugs are common on multiple vehicle lines including older Corvettes but I don't want to go down the rabbit hole too far here.

 

[ccgillett]

Closer and closer...the fusebox bracket/holder are installed, bunch of connectors are hooked up. I'm waiting for a fusebox from a recycler in Connecticut to show up by Thursday - there I will find the bottoms to the multi-plugs so that I can install the fusebox "by the book". Looks like I might have a spare fusebox for someone who needs it later. I found the fusebox in eBay for $80, and my offer of $50 including shipping was accepted.

The battery and hold-down clamp are installed. Battery needs to be charged and perhaps tested but should be good to go. A few minutes ago I checked all my cooling system clamps and connections, and then filled the cooling system. Everything seems fine there, little concerned about the drain plug in the radiator...seems like it's dripping about 1 drip per hour. It was a little loose so I tightened it. Doesn't seem like there is anything broken in the aluminum or welding, and it seems to be leaking less as it sits. Fingers crossed. Finally, I had a little drama with the ring that mates the fuel pump to the tank...I couldn't get the connector to go in cleanly. So I re-did the bolting job to make sure everything was clearanced correctly. Then I removed one of the nuts, got the connector installed cleanly, and then re-tightened the nut.

As I work my way through connecting everything I wanted to check a couple things. First, do we all agree that these are all grounds? The silver-colored one terminates at the engine, and the copper-colored ones are from the wiring harness. I believe they are all ground but I wanted to confirm as I search for a place to terminate them on the frame:

I have a number of connectors from the engine wiring harness that I'm not sure about. There are instructions to "clean up" the harness which I will follow later. I did wonder about the one pictured, which runs off the engine harness at the back of the engine (where "back of engine" means the side with the butterfly closest to the firewall). Does anybody know what this one is and where it connects?

 

[Ross]

The 2 copper colored tabs are grounds, the silver one might be an engine ground. Check the other end of it, and see if it goes to the engine bell housing, or if it goes to the starter lug. There is a big wire from the starter to the fuse box jump post that is 12V+.
That red connector looks like one of 2 fans for the radiator. Our goblin doesn't use the ~12" AC fan, and the ~14" engine coolant fan is routed up front.

 

[Gtstorey]

By silver terminates at the engine, you do mean just bolted to the block or transmission? If so, yes ground to the chassis.

 

[Robinjo]

The brown/red connectors are the old Cobalt cooling fan plugs. They aren’t needed.

 

[ccgillett]

By silver terminates at the engine, you do mean just bolted to the block or transmission? If so, yes ground to the chassis.

Yup this appears to be the case.

 

[ccgillett]

The 2 copper colored tabs are grounds, the silver one might be an engine ground. Check the other end of it, and see if it goes to the engine bell housing, or if it goes to the starter lug. There is a big wire from the starter to the fuse box jump post that is 12V+.
That red connector looks like one of 2 fans for the radiator. Our goblin doesn't use the ~12" AC fan, and the ~14" engine coolant fan is routed up front.

Awesome, thank you!

 

[comegetjoe]

Where are we now? It's been a couple months.

Can you snap a couple photos of how your fuse box is mounted to the chassis?

 

[ccgillett]

Where are we now? It's been a couple months.

Can you snap a couple photos of how your fuse box is mounted to the chassis?

I really LOVE this accountability callout...seriously.....thanks for that! I need to get back on this car and I haven't had time to touch it in a while. The combination of family and work responsibilities, business travel, etc. have really gotten in the way. Also the Fabulous Daughter, who has had her driver's license for almost a year had a bit of an "oh ****" moment while out and about in my daily. So, naturally, I did what every car guy does -gave her my credit card, told her to buy a bunch of parts, pointed her to the tools, and said "fix your mess"....

I didn't turn a wrench on this one, just kept an eye on things, answered questions, and helped her a bit negotiating with the paint guy who sprayed the bumper cover. She figured everything out and did it all on her own. Not shown is her work under the car replacing the floor, and working on the retractable headlight sprayer, etc. She's got one more grille to install (the long thin one at the bottom of the bumper cover), but wrapping up high school, graduating, and scheduling college orientation got in the way. I'm a proud dad, and I figured only other car guys would appreciate her efforts.

Back to Goblin stuff, the fuse box mounting to the chassis is "done" I think. I'm not terribly happy with it, but I'm gonna see if it will hold up. Recall that this was bought from someone else, so not all the pieces/parts were there. Plus this being Chassis #13 I don't think they had worked out the fitment for everything with the LNF engine. Here's what I came up with:

I may have mentioned this in a previous post, but the hardware to get the box up and above the shifter attach points, cooling hoses, etc. wasn't in my parts boxes, so I grabbed some stuff from the hardware store and made something. Side note - no clue why that engine mounting tab is so scratched up. I'll have to clean that up. Also, I cobbled together the pieces that connect the right side of the box to the chassis. There was no way on my frame to connect it the way it looks in the DF build photos. I am going to take it apart again to paint the bare metal bracket, and when I reassemble it I will use Loctite on everything as I worry about it vibrating apart.

I remain perpetually "this close" to first engine start, and maybe just maybe I can get some garage time this weekend....

 

[comegetjoe]

Pictures are on point! Thank you!
Happy to know we're both part of the S Family of Audi. I truly enjoy my turbo SQ5.

Get in that garage! I'm excited for you!

 

[Desert Sasqwatch]

Way to go Dad! The life lesson of responsibility and ownership of the problem is something she will never forget and hopefully carry through out her life. Both of my kids - son and daughter - went through this same exercise and it was one of the best things I ever did for them.

 

[ccgillett]

Ok, trying to get back to this project after months away...common theme. I'm ready to turn the key and see if this thing is electrically alive, except for those 3 pesky grounds. Where did you guys ground these on your frame?

I'm considering the engine mount which is bolted to the frame, I'd need to remove the fuse box temporarily in order to drill a whole, not my favorite idea. My other idea is to drill a hole into one of the diagonal tubes and use a self tapping conductive screw to secure them. One of the challenges is that I don't have much length to play with in terms of running these wires.

What did you guys do, pictures help small brain people like me...

 

[Rttoys]

There should be a ground stud at the yellow circle. One of the TC guys need to confirm though.

Red circle, make sure is a ground. I think it is, just want to confirm.

 

[ccgillett]

There should be a ground stud at the yellow circle. One of the TC guys need to confirm though.

Red circle, make sure is a ground. I think it is, just want to confirm.
View attachment 48973

Pretty sure the red circle is a ground, should only be one connector attached to the positive stud in the fuse box right?

Re the yellow circle, so you mean right thru that support? I have a grounding stud I bought a while ago, I could drill a hole there I suppose.

 

[Rttoys]

Red circle wire, Follow it to where it ends. Should be block or trans. If I remember correctly. That would be a ground then. Just making sure. Others have mixed the powers and grounds. Just making sure.

here’s the stud on mine. Need to confirm with a tc one of they are different or newer ones are different. There may be one somewhere else, but that’s where it is on mine.

 

[Gtstorey]

Tc does have a stud under the fuse box.it should have multiple grounds on it.