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Old 14th August 2011, 03:08   #151
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Default Re: Project MG 416 W

Quote:
Originally Posted by IndrojitSircar View Post
Now here when you say you used the complete gypsy wiring, do you mean to say all the wiring expect the engine wiring right?
No I meant the complete Gypsy wiring including the engine wiring. Gypsy wiring has two main parts - engine cum chassis wiring and the dash board wiring. There is also a third small battery wire. The engine cum chassis wiring also has coupler points for headlights, turn indicators, horn, fuel pump, fuel gauge, reverse switch, 4X4 switch, rear lights etc. so you have to use it. Dash board wiring has to be used for obvious reasons. I have cut off all the engine coupler points from the Gypsy wiring, but not the complete wires as I may have some use for these wires later on for adding some accessories.


Quote:
Originally Posted by IndrojitSircar View Post
Can you share the wiring diagrams either here on the email ? Do you have the part number for the Baleno EuroIII workshop manual ?
I can give you the Gypsy Euro III wiring diagram but not the Baleno diagram. I dont have the Baleno wiring diagram myself. I was still able to do it as I had the Euro II wiring diagram, damaged complete wiring and a running Euro III Baleno. The damaged wiring I had was from a car that had a right hand side collision so it was good till the combi meter. Still I got 75% info about 'which wire goes where' from that only, got 20% help from the euro II wiring diagram (different couplers but same wire colour) and 5% from the running vehicle.

No, I dont know the Baleno E-3 manual part number. The Baleno E2 wiring manual is separate from the main workshop manual. I will give the part number for that to you, but try sourcing the E3 wiring manual. I had help from other sources so didnt felt a need for one.



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Originally Posted by IndrojitSircar View Post
I understand that. Now the engine wiring that i have has 3 couplers, two go into the ECM and the third one is much bigger perhaps connects to the wiring that feeds the fuse box, meters, and other components on the Dash board.The wiring and has some cutting and taping done on it and i am going to use a brand new wiring and will discard the existing one.
Well a new engine wiring costs 10K plus, so its your call if you can 'satisfactorily repair the wiring' or 'go for a new one'. Any and all joints in my wiring are soldered and insulated by heat shrink tubing. Cannot say anything about your wiring without looking at the damage.

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Originally Posted by IndrojitSircar View Post
Now the third coupler that you talk about which is the one i talk of also is the one you had to modifiy? I have this third coupler wiring missing, so do you suggest i buy a new gypsy wiring and buy a used Baleno wiring to do this modification of the couplers in it or i buy a new aleno wiring and lots of wire bunched up at the back ? The advantage of using the baleno wiring i feel would also give me an accurate tacho reading as the baleno wiring has the wiring for the tacho as it has a tacho in the main instrument cluster? Your views on the same please.
The third coupler in question if I remember correctly is near to the Big Fuse Box. I removed that coupler and made a new one near the two to the ECU, which is joined to its mate installed on the dash board wiring of Gypsy. I think there is 90%+ chance of you salvaging your current engine wiring harness. Just check if this wiring has all the engine coupler points intact with no internal wire breakage.

You are right about tacho reading. I have also made provisions for the Tacho running via ECM to be installed later.



Quote:
Originally Posted by IndrojitSircar View Post
This is going to e something interesting to see.
Interesting it surely is. Best for anyone who wants to use the car as a daily drive. Once I went to Mayapuri in the Gypsy for the hard top. On way to his godown, a shopkeeper sitting with me watched in awe as I maneuvered the Gypsy through some very narrow lanes and also did a couple of quick U turns with one hand on steering and other on gear stick(the way I usually drive).
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Old 22nd August 2011, 02:06   #152
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Default The Final Product

hi all...

I was busy relocating to my new job location & I am glad to see the thread buzzing.

Let me post the final outcome of my project.

Feel free to give suggestions

Works done on Phase 2

Tub off the chassis, end to end tinkering & rust proofing.

1.5 inch body lift -

1.5inch C sessions were welded (mig welding) to body mounting points.

Chassis was given anti rust coating after this lift job.
Mean while the underside of the shell underwent minor works( it had anti rust coating)
New mounting bushes were used to mount the body back in position.

Steering column required modification as a result of the lift. Falcon's engine bay was a bit congested owing to bigger radiator & power steering box.We replaced the rag joint with universal joint.

The brake lines & fuel lines required a little rerouting.
The gap between body & bumper owing to the lift was covered by extending the lower portion of front grill & the front fenders.
I felt that its cool to leave the gap.
But Sugith (paint shop owner) was against this idea & he got it fabricated overnight.
The Fuel hose cover (can be seen through rear right wheel arch) also required 1.5 inch extension


Hard Top cabin.
I had plans for a rally cabin & roll cage.
Later I dropped this idea.
I wanted an airy cabin with decent space, unique looks & strength to handle a roll over. It shouldnt look like a tinbox & weight should be As less as possible.
My requirements were discussed with a veteran tinker man(55 yrs old) who used to make amby's body panels in Brass & sketches were made.
Thus the new cabin got ready. He first made a frame out of box session tubes & did the double walled frame over that.
Sugith insisted not to use rubber beading to mount the glass to retain unique looks.
The result can be seen on photos.

Better Seats
I managed to smuggle those Type R seats from UAE in 3 different consignments. As expected , the in transit conditions froced me to redo its outter cover.

Momo steering wheel
Thanks to Anish Vincent for sourcing me this wheel. It was direct bolt on.

to be continued..............
WIP pictures will be uploaded with description
Attached Thumbnails
Project MG 416 W-after-side.jpg  

Project MG 416 W-final-touchup.jpg  

Project MG 416 W-workshop-guys.jpg  

Project MG 416 W-momo.jpg  

Project MG 416 W-helipad-front-view.jpg  

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Old 22nd August 2011, 09:56   #153
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Default Re: Project MG 416 W

Sree,
Nice update bro!!! Falken looks great now,good transformation, even i could not have helped you in body work with this much perfection in Erode. keep going. Did you Re-do the ECM wiring after Tinkering & painting?
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Old 22nd August 2011, 10:22   #154
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Default Re: Project MG 416 W

Looking good man, i like the cabin especially, really roomy and airy as you mentioned. What is the cabin made of?
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Old 22nd August 2011, 10:49   #155
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Quote:
Originally Posted by Jaggu
Looking good man, i like the cabin especially, really roomy and airy as you mentioned. What is the cabin made of?
Thanks bro...
It's actually a tinbox(mild steel)
Almost everyone had this doubt.
I've seen guys knocking on the cabin to check if it is fiber.

Ashwin,
The guys at w/s boiled their brains a bit on the wiring harness routing.
Finally they located an ex-gulf mpfi specialist who had scanning tool, & he approved their work.
There was little scope for error as it was bunched in the right way in phase 1
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Old 22nd August 2011, 15:20   #156
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Default Re: Project MG 416 W

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Originally Posted by MexXxentric View Post
Hellow Friends,

I am planning to unleash my dream project. - MG 416 W

The target is to install a Baleno's 1.6 liter engine in Gypsy King ,and retaining the 4x4 of course.

Experts, please advise me on the feasibility of the project, expected bottle necks and problems, hardware requirement, legal issues, approximate cost involved, etc etc.
That's nice bro. Have you settled the VSS bug? And were you able to get the speedo nurling??
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Old 22nd August 2011, 21:14   #157
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Default Re: Project MG 416 W

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Originally Posted by ashvar87 View Post
That's nice bro. Have you settled the VSS bug? And were you able to get the speedo nurling??
The speedometer is working. but the No VSS bug is yet to be fixed.
For that I need MPFI King's meter console.
I sourced the speedo gear(SGP) & new speedo cable through MASS.
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Old 31st August 2011, 23:14   #158
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Default Re: Project MG 416 W

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Originally Posted by autoholic View Post

The third coupler in question if I remember correctly is near to the Big Fuse Box. I removed that coupler and made a new one near the two to the ECU, which is joined to its mate installed on the dash board wiring of Gypsy. I think there is 90%+ chance of you salvaging your current engine wiring harness. Just check if this wiring has all the engine coupler points intact with no internal wire breakage.

You are right about tacho reading. I have also made provisions for the Tacho running via ECM to be installed later.




Interesting it surely is. Best for anyone who wants to use the car as a daily drive. Once I went to Mayapuri in the Gypsy for the hard top. On way to his godown, a shopkeeper sitting with me watched in awe as I maneuvered the Gypsy through some very narrow lanes and also did a couple of quick U turns with one hand on steering and other on gear stick(the way I usually drive).
Hi,

What's the status on your car? Also can you give me the part number for the Gypsy Wiring manual and Also the Baleno Euro II ?

Thank you

Regards

Indrojit Sircar
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Old 5th September 2011, 22:22   #159
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Default Re: Project MG 416 W

Quote:
Originally Posted by IndrojitSircar View Post
Hi,

What's the status on your car? Also can you give me the part number for the Gypsy Wiring manual and Also the Baleno Euro II ?

Thank you

Regards

Indrojit Sircar
The status of my car is the same as a month ago. Too busy in a very very important personal problem to even have a look at it.

Baleno Euro-II Wiring Manual Part no. 99512M60G00-74E
Gypsy Service Manual CD-Rom Part No. 99016M82C00-74E
(The CD-ROM has service manuals of all the variants, a very useful tool)

Try getting the Baleno Euro-III Wiring Manual if you have the Euro-III engine+Wiring+ECU. (I don't have the part number for that.)
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Old 14th September 2011, 17:15   #160
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Default Re: Project MG 416 W

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Originally Posted by autoholic View Post
Gypsy Service Manual CD-Rom Part No. 99016M82C00-74E
(The CD-ROM has service manuals of all the variants, a very useful tool)
Are you sure that it covers Gypsy King MPFI also, I checked with AMCO and they said this manual is for Old gypsy, as per him the part number for Gypsy King is 99016M82C01-74E, pls let me know the cost also.

Thanks!
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Old 14th September 2011, 17:44   #161
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Default Re: Project MG 416 W

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Originally Posted by Crazy4Power View Post
Are you sure that it covers Gypsy King MPFI also, I checked with AMCO and they said this manual is for Old gypsy, as per him the part number for Gypsy King is 99016M82C01-74E, pls let me know the cost also.

Thanks!
This CD has manuals for mg410 to mg413W EuroIII. Read the CD Part Number off the cover so it is 100% correct.
The other part number you have may also be correct with the addition of EuroIV manual.

Costs below Rs300/-(I dont remember the exact price).

Last edited by autoholic : 14th September 2011 at 18:00. Reason: addition
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Old 9th October 2011, 22:58   #162
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Default Re: Project MG 416 W

Quote:
Originally Posted by autoholic View Post
This CD has manuals for mg410 to mg413W EuroIII. Read the CD Part Number off the cover so it is 100% correct.
The other part number you have may also be correct with the addition of EuroIV manual.

Costs below Rs300/-(I dont remember the exact price).

Hi,

Its been a while, what's the status on your car? Some pics pleasE?

Regards

Indrojit SIrcar
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Old 24th November 2011, 01:51   #163
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Default the complan effect

I finally found a stock gypsy to park Falcon nearby & check the actual difference
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