New wiring harness...who has done it?

Zack1978 · Samba Member Joined: June 07, 2006 Posts: 544 Location: NJ

Hi everyone,
So as the title indicates, has anyone done a full wire harness replacement on a running and driving (ie body still on pan) Karmann Ghia?
On my 72 coupe, many of the wires have seen better days. Sadly some PO's cut spliced, hacked, etc at the wires over the last 43 years.
How bad of a job is it? Is the quality of the currently available harnesses good? I would like some insight into this job.

Thanks,
Zack
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1972 Coupe

jason_hamilton · Posted: Sat Oct 03, 2015 12:21 pm Post subject:

I did a 67 cabrio a few years ago using one of the harnesses from KGPR. Excellent quality and a straightforward install. Re- and re-'d in one weekend, but I know my way around wiring fairly well. Have an experienced buddy help or get the Vol. 9 Bug Me DVD (also available at KPGR) and have a wiring diagram available.
So nice when it's all done and working properly.
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Jason Hamilton
1969 Karmann Ghia coupe
@MiddleAgedHoon

wcfvw69 · Posted: Sat Oct 03, 2015 12:58 pm Post subject:

If you have basic understanding of wiring and electrics, it's an easy project to do. I did a convertible bug with a wiring works kit. It fit perfectly, had good instructions and I also used the Bentley electrical diagram as well.
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boinkffd · Posted: Sat Oct 03, 2015 12:58 pm Post subject:

I installed a new one during my 58 restoration. It was a pain in the butt as its a 6 volt and everything had to be grounded. Plus I had to install all the components .

You will have a much easier install as your electric parts are already in place.

swavananda · Posted: Sat Oct 03, 2015 1:21 pm Post subject:

It is sort of like paint by numbers, connect the dots,jigsaw puzzle. All of the wires are color coded, white with red stripe , black with green stripe etc. follow the wiring diagram ton where they go and take your time. Not to scary once you have it front of you.

lonotch · Posted: Sat Oct 03, 2015 2:23 pm Post subject:

Before install I would put the new harness out in the sun to make it more plyable, and work the kinks out.
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runamoc · Posted: Sat Oct 03, 2015 6:27 pm Post subject:

To keep the correct colors on the ends of a mangled wiring harness, I staggered splices in the main part of the harness so there would be enough length at both ends of the harness for the short wires to make the required connection. Wrapped it with spiral wrap and black tape. Cool

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andk5591 · Posted: Sat Oct 03, 2015 6:56 pm Post subject:

Have never done a Ghia, but cant see how it would be much different than a bug. In the middle of one right now and its not bad at all. I use Wiring Works harnesses. Not sure how many I have done at this point.....3 or 4? Biggest problems were because someone thought he didnt need to follow the instructions..... Embarassed

But every one I did was with the interior pretty much gutted. But its not required. Just that I was building cars from scratch and it makes more sense to install the harness before the carpet.
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bluedot · Samba Member Joined: April 25, 2013 Posts: 439

I love wiring.

But what I've done is keep the factory 6v wiring as a "trigger" system for a new 12v harness where I needed to upgrade wiring sizes for higher amperage lighting, etc.

That way the old switches aren't running the voltage, and a new fuseblock added. Check my posts for more info.


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