I had a bit of a frustrating day yesterday. I attempted to put the extension harness on the underside of the passenger seat in a way that would allow me to relocate the control module to a location that wouldn't interfere with the movement of the seat.
The difficulty is that the space between seat and adapter bracket is really tight, and the space between the adapter bracket and the floor is really tight, so my assumption that I could relocate the module to the bottom of the bracket isn't necessarily true. The secondary problem is that the space between the two crossbars of the adapter bracket is less than the range of adjustment on the sliders, so there is no single location for the module or the wiring that doesn't hit at one end or the other. It doesn't matter which side things are mounted to, if it clears the rear crossbar when all the way back, it will hit the front crossbar before sliding all the way forward, and vice versa.
I contemplated cutting the bracket apart and welding things back together differently, but I honestly think it would be easier to go with the other wild idea that crossed my mind of ditching the extension harness, pulling the seat bottom cushion out of the seat, peeling the cover off, hollowing out the foam to tuck the entire fricking module inside the seat cushion hollow, plug the module directly into the sensor, shove it into the hollow, and then reinstall the bottom cushion upholstery.
Neither one was going to happen starting on a Monday night at 7:30pm, so I tried a half dozen different setups before I went with this setup, which seemed OKish at first glance:
Seat all the way back, module ziptied to the seat bracket in the left of this view, extension harness I built plugged in and forming a big loop. The module brushes seat and maybe floor on occasion, but I don't think it will be a hard interference. The connector to the vehicle-side harness is still in a decent location, which is another consideration.
Bench mock-up of seat all the way forward position with the same setup as above. Extension harness has a tiny bit of slack, and the grey connector to the vehicle-side harness still seems in a doable position. Unlike lots of my other mockups, this one didn't interfere with the sliders at either extreme.
I went for it and installed it in the car, did a slide forward and back test, reconnected the battery, aaaaaaand....airbag warning light!
No idea what went wrong, but I tested functionality on the passenger side occupant sensor and it isn't working. It doesn't switch on when key on sitting in the passenger seat, so something isn't connected correctly, or came disconnected.
At this point is was late enough I was throwing in the towel for the day. Frustrating to say the least.
I will solve this long-term, but for the short-term, 95% of my usage is me alone, so I'll get the passenger airbag solved before taking anyone for a ride.
With the first sunny and warm spring weather of the year forecast for the rest of the week, I'll be taking a bike or the Cappuccino with the top down to work for the rest of the week, and bring the FR-S out on Friday in time for the trackcross and trackday three-day weekend coming up.