Project: K.I.T.T. Blog
After work on Monday I removed the hardware from the drivers side window. There were four rivets that needed to be removed in order to get everything off of the glass. I am used to being able to just drill out the rivets, but these rivets are not traditional rivets. They have a long threaded shank protruding through the rivet head. I knew that I would have to use my high-speed rotary tool to cut off the shanks before I could drill them out, so I started with that.
You can see what the threaded shanks look like in this picture. It almost looks like you could just thread it out.
It was so easy to cut through the shank with a cutting disc that I used the dremel to cut the head of the rivet in half, stopping just before the metal track.
With the head removed I was able to pop the pin through the other side using an ice pick.
I used the cutting disc to grind the shanks flush on the remaining three rivets. I briefly tried to drill the rivet out old-school-style, but found the cutting disc so much easier and faster.
The other three rivets came out just as easily as the first.
I removed the track and hardware from the window.
Here is the drivers side door glass with all of the hardware. I will not be saving the glass.
Today after work I removed the hardware from the passenger side window.
I started again by cutting all of the shanks off flush and found that I actually could pop the shank out before cutting through the head of the rivet. This made it even easier to see how far I needed to cut on the head.
Here is the passenger side door glass with all of the hardware I removed. I will not be saving the glass.
We changed the oil in both the Freestyle and KARR today and also took care of a few items that have been on the to do list. I cleaned KITT's old door glass so we can remove the hardware as it will be needed on the new glass we have. I took these pictures more for future reference than anything.
I was going to clean all the old grease and dirt off the window track, but decided that it will be much easier to clean once it is off the glass.
I used our foaming window cleaner and let it eat away at the grime on the glass.
There are four rivets that will have to be drilled out and three plastic inserts. I will end up replacing the rivets with small bolts and nuts.
One of the plastic washer style plugs in the passenger side door glass is broken and one was cracked in the driver side. I am not sure what these are called, and cannot find them in the service manual. I am going to see if I can source some replacements.
KARR's passenger seat was missing the reclining lever when I bought it.
One of my Christmas presents from Mom and Dad was a new passenger seat reclining lever:
Here I am installing the new lever.
Here is the new lever installed!
Mom and Dad also gave me a Fiero GT blackout for my third brake light for Christmas.
Here's how the third brake light looked:
Here I am testing the fitment of the new blackout.
Here is how the brake light looks now!
The reflection seen on the deck lid is more true to life than how the brake light shows up in this picture.
Thanks again Mom and Dad!
As promised here is a more detailed unboxing of all the Painless Performance wiring harness products we ordered. Since I have not yet had a chance to read all the literature that comes with them, I am not going to go into a lot of written detail. I think the pictures speak for themselves and I would I hate to identify something incorrectly.
KITT's chassis harness - Painless Part #10201 28 Circuit Classic-Plus Customizable Chassis Harness -GM Keyed Column
They included a sample card with the chassis harness that shows the two types of wire protection sleeves they offer: ClassicBraid and PowerBraid. I chose the PowerBraid.
Close-up of the look and texture of the ClassicBraid.
Close-up of the look and texture of the PowerBraid. The PowerBraid is exactly like the cable sleeving that I use at work and I like the look and feel of it.
Each wire is labeled as to its function every few inches along the entire length of the wire.
KITT's Fuel Injection harness - Painless Part #60101 1982-93 GM 4.3L V6; 5.0,5.7 & 7.4L V8 TBI Harness Std. Length
They included another PowerBraid/ClassicBraid sample in this box. I took a picture of the backside of the card this time.
Painless Part#70921 PowerBraid Fuel Injection Harness Kit
Painless Part#70920 PowerBraid Chassis Harness Kit
My next step will be to thoroughly read through the installation manual and see what other materials and supplies I will need. I know right off the bat I will need 14 gauge black TXL wire to complete the ground for most of the circuits. This is exciting but yet a little daunting...
This anniversary feels a little bitter-sweet. It is always exciting to celebrate another year gone by for the project, but this time I feel like "Man, has it really been four years?".
Setbacks just happen with any project, I know that, but I think I let the painting fiasco affect me more than it should. I lost motivation as a result. I distracted myself by getting caught up in other things and just did not put a priority on KITT. I tried several times to reestablish the pace Sara and I had at the start of the project, but so far it just hasn't been the same.
Right now I am all fired up about starting on the wiring, and with the added 'kick in the butt' this anniversary delivers I have something to announce:
I am back in the game! :D
We got KITT's 1983 Pontiac Trans Am body four years ago today. Here is what he looked like on January 14, 2012...
Here is what he looked like three years ago on January 14, 2013...
Here is what he looked like two years ago on January 14, 2014...
Here is what he looked like one year ago on January 14, 2015...
and here is what he looks like today, January 14, 2016.
Aside from marking four years for Project: K.I.T.T., today holds another special significance for me. 18 years ago today I met my soul mate. She didn't know then that I had a crazy dream of taking her everywhere in KITT someday, but I can tell you this - the project would have never have gotten this far without her. I love you Sara!
It has been awhile since I have posted a picture of KITT. Well, here is what he looks like right now.
Lately the blustery winter wind and snow has been blowing the tarp that currently covers KITT around every time the garage door was opened. I decided to do something about that after work today, so I secured the corners of the tarp together with a bungee cord in the front and the back of the car. This keeps the tarp taught and should help with the wind.
KITT looks nice, snug and warm don't you think?
It has been far too long since there were regular updates on Project: K.I.T.T. That is going to change starting now! We decided to dive right back into the project with something big, so we ordered KITT's new wiring harnesses. This is truly where all the magic begins. KITT would not be KITT without a solid electrical harness powering all his awesome systems and electronics.
As previously discussed, we have decided to go with a new harness entirely and wire KITT from scratch. There are just too many variables when trying to reuse an old harness. We will still need many of the connectors from the old harness, but all the wiring will be new.
We decided to go with harnesses from Painless Performance. I have done a lot of research and Painless Performance seems to have the highest quality custom harnesses, offering the most flexibility and great support.
KITT's chassis harness will be Painless Part #10201 28 Circuit Classic-Plus Customizable Chassis Harness -GM Keyed Column
PowerBraid is a flexible, semi-rigid material, with a tough woven texture and appearance to enhance the look and protect the insulation of any electrical wires. I use something similar to this at work for all of our computer cable management. This stuff is awesome and much more resilient that the old plastic style sheathing.
KITT's Fuel Injection harness will be Painless Part #60101 1982-93 GM 4.3L V6; 5.0,5.7 & 7.4L V8 TBI Harness Std. Length
Painless called me today to verify my order, and told me it should ship out today. I am really looking forward to receiving it, and I will do an unboxing video when it arrives!
We have been working with KITT on perfecting his vocal recognition protocols and he is getting really good at recognizing and responding to just about everyone that stops by. He would benefit from hearing a more vocal samples however, as there can be so many variances in the way we talk and our varying accents.
There was enough interest from our followers, so we are hosting a video Hangout, to give anyone interested a chance to say "hello" to KITT. Please keep in mind that because KITT will be learning your voice all you will be able to say is "hello", but if we have enough people help with this we might be able to let you talk to him more in the future.
Mark your calendar and join us on Hangouts on Sunday, December 13 at 7:30 PM CST.
Are you going?
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