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Mon Jul 04, 2005 7:47 am

Hey all,
I spend most my time in the Thing forum ( I have a '74), but I am currently shopping for a Baja, so I figured i'd drop in here too..
My main question is about wiring harnesses. I am looking at a '69 plain jane baja, and the wiring is a mess. I'd want to do a complete rewire. Are there any companies that make a VW wiring harness with the blade style fuse block, and more modern hookups?
I know Painless makes them for muscle cars, but they don't list anything for a VW...
Any help is appreciated!

Mon Jul 04, 2005 9:27 am

I'm in the same boat. I've been looking for the same thing for a while. It does not seem to exist. The only way I could come up with a solution is to get the Painless fuse block and just adapt from there.

Mon Jul 04, 2005 10:02 am

They sell buggy style witing looms at places like Mooreparts.com and pac customs. You may have to add some stuff for turn signals and such but i believe the kits are fairly complete. My baja has most of it's original wiring that was saved and new style fuse boxes were adapted, however most of the relays were eliminated. I prefer this set up because if i have a problem i car look up wire colors on the wiring diagrams on this site.

Mon Jul 04, 2005 10:07 am

Yeah Hank,
That's what I am afraid of... I am severly electricaly challenged. I helped my buddy with his '56 Chevy, but that was a plug and play harness, and Very easy to do.
There are "universal" kits out there, but from what I understand the wires are all terminated, so you'd have to splice any that are not correct length.. Maybe that's the only option.... :?:

Mon Jul 04, 2005 10:15 am

Baja5,
I've seent the buggy kits. I have thought of just getting a blade style fuse box, and mating it with the bug wire harness... But again, I am very NOT electrically inclined. I guess that could be electrically DE-clined..?
I'd have to find someone to help with the conversion.. and that noramlly costs $$$.....

OH, BTW, SWEET RIDE!!!!!!!!!!!!!!!!!!! I have the same "dreams" for mine....Someday...
Very nice... is Ocotillo wells in AZ??

Mon Jul 04, 2005 10:47 am

Thanks, no, ocotillo wells in in east san diego and imperial counties. Wiring isnt all that tough. it's more intimidating that anything.However knowing how to properly use a dvom is very helpful.Just take your time, start with the easy circuits like brake lights until you get the hang of it.And probably most importantly, always make sure your ground connections are clean. alot of people overlook the ground side of circuits.dirty grounds will cause voltage drop and make lights dim.

Mon Jul 04, 2005 12:21 pm

I got frusturated with my stock wiring as well. I saw it as a fire or problem just waiting to happen. I wasn't able to find any aftermarket setup that could be easily used. So, I started from scratch and built my own. Like Baja5 said, it is more intimidating than anything. I decided to upgrade several components along the way such as adding relays to all of my accessories, running wires to the apporpraite locations, adding safety features, using the pin style fuse blocks, and configuring a relay system to allow the use of dual element turn signals and brake lights.

There are some guys with great wiring info on http://www.dune-buggy.com

SHMO

Mon Jul 04, 2005 12:42 pm

SHMO, just out of curiosity what relays did you run? I really didn't use any for headlights or anything because it just adds more wiring and more to go wrong. All a relay is is a switch that uses low current to turn on a high current device( i'm sure you know this, i said it for the other guys).As long as the proper guage wiring is used and the circuit is properly fused then there are very few relays you actually need. Starter and turn signal.

Mon Jul 04, 2005 5:06 pm

Baja5,

Personally, I like to use relays whenever possible. Like you said, they are basically a remote switch. However, they are designed to handle much higher loads and live a longer life than a typical toggle switch. Using relays takes a lot of load off the switches and circuits. Things can also be easily tied together with the use of a single relay if you choose to do that, like having 4-way flashers for instance. When the switch is flipped, you have flashers, when it is off you have normal function over your turn signals and brake lights. That is just one example.

On my car, I have a relay setup for my headlights and taillights, another for off road lights and backup lights, one for accessories, one for the ignition system and several that control the function of my turn signals and brake lights. My turn signal and brake light setup requires several relays to complete the circuit through the factory turn signal switch. Using relays here, allows me to have everything work through a single taillight with a dual element bulb. You cannot do that through the factory turn signal switch without using relays. That is why most off road VW’s you see will have a separate tail/brake light and turn signal light.

All of the relays in my car are "ignited" through my ignition switch. Therefore, my ignition switch sees very little amperage draw because it is only charging the relays, not actually carrying the load of EVERYTHING in the car. The same holds true for my toggle switches. They see very little amperage. Therefore the switches should last a long time. And, things like headlights and especially off road lights draw a lot of amperage. Typically it is hard to find sufficient toggle switches to handle this load, and without the use of a relay over time the switch will fail.

That’s just my take on it. I am by no means an electrical guru….haha

SHMO

Mon Jul 04, 2005 7:06 pm

I understand wanting to keep from overheating switches and such. my stock turn signal and ignition switches are gone however and all of my circuits have their own switches, about 9 in all so running 10 or so amps through each switch is no big deal.. and my flasher is and old school 2 prong unit, no more than 3 amps of so i'd guess. i was just curious.

Mon Jul 04, 2005 7:17 pm

How are you powering up your fuse panel? Is the system hot all the time? Do you run a circuit breaker or fuse at the battery?

SHMO

Mon Jul 04, 2005 10:37 pm

I have separate fuse boxes, one powers all the ignition components and flashers and one that is hot all the time for the lights.Both are fused from the battery.I may ghange to a circuit breaker though, but i haven't had any electrical problems yet.

Tue Jul 05, 2005 10:14 am

Wiring kits under $350 are not all that good.

Earl Duty's book shows a great step by step on how to do this....

I'd pull custom again if doing this.

T.

Wed Jul 06, 2005 3:11 pm

I just noticed a company on Ebay selling a blade fuse wiring kit that you may want to check out.

On this subject, what is better about blade style fuses than the old style glass ones? I thought it was nice to look at the fuses and easily see the burnt one. My experience with the blade ones is that you need to pull each one out to check them.

Wed Jul 06, 2005 3:15 pm

Blade style fuses typically have a better fit in the fuse box and run cooler than glass fuses,They are also easier to find in a jam. ever had to borrow a spare fuse? good luck finding a glass one, or an original ceramic one for that matter.

Wed Jul 06, 2005 6:26 pm

But one good point thing glass fuse holders is, it is a whole lot easier to use a piece of wire or some wadded up aluminum foil in an emergency. With the newer style fuse, you gotta get McGyverish. I suppose a paperclip bent in just the right way might work...lol

SHMO

The writer assumes no resposibility for missused fuseblock, or condones inproper use of an electrical device. All opinions are soley expressed in an attempt to make a humorus comment.

Wed Jul 06, 2005 7:27 pm

I'm also really big on relays. My rail has many. Baja will have them also for all high current lights. Anyone know of a cheap source for Bosch type relays? Thanks

Wed Jul 06, 2005 8:48 pm

Having to use a paper clip is the reason my car along with just about all new cars have head light,tail lights,turn signals, and all of the essential components on seperate circuits. if my headlights quit i can use my offroad lights.I know there are times when it is necessary to improvise but if you can do all you can to avoid it then that is the route i recommend.

Wed Jul 06, 2005 10:34 pm

A good source for Bosch style relays is "Parts Express", I use that supplier because they also sell a Bosch style socket that is end gangable. Also, "All Electronics" has some Bosch style relays and what appears to be the same end stack sockets,but I have yet to order from them. You guys that are crafty could go to a yard and look at underhood electrical centers from various manufacturers, mid 90's GM F-bodies (camaro,firebird) have one I've retrofitted that has enough standard blade fuse locations for any project car, and 8 Bosch style sockets. It is all one piece, and has a front and back cover. The only labeling on it's outside just says "FUSES" as well. That is ideal for what we're doing, my avatar is getting one as well. If you find some type of factory electrical center like this, and decide to do it, I advise buying 2 identicle units. It takes a little practice to extract the little plugs so it's good to have something to practice on, also you then get a better assortment of internally ganged things to customize you're arrangement. This really isn't a challenging operation, it just takes some thought and draw a good schematic first. I use an ammeter to test everything after the refit so I can see how much current a circ is drawing and pick the right fuse for it. Hope this helps. Imp558 PS: ROCK ON relay users of the board! Relay is the only way.

Thu Jul 07, 2005 11:31 am

Imp,

did you get my PM?

SHMO