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laughlin
Samba Member
Joined: July 19, 2013
Posts: 48
Location: flat rock, indiana
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 Posted: Tue Jul 30, 2013 6:15 pm Post subject: Wiring harness - Anybody ever build their own? |
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| Has anyone ever built their own harness? Have any drawings? I've looked at rebel harnesses but so many too choose from and I just wonder if could be done cheaper. |
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Roys_Big_Toys
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Joined: April 30, 2011
Posts: 225
Location: Richmond, VA
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| Posted: Tue Jul 30, 2013 6:39 pm Post subject: |
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Naw, That's crazy talk. Wierd lern ta spel? LOL. Rebel Wire is the TOPS!
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I'd rather be an hour early than 5 minutes late. (Mine)
"It's not a hobby, it's an addiction" (My wife)
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Original Meyers Manx
Berrien LKD Warrior Ecotec 2.2 w/ Bus 091 Trans
Original 2 sided Meyers Manx Dealership sign
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pallen
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Joined: February 15, 2012
Posts: 589
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Buggy68
Samba Member
Joined: July 25, 2013
Posts: 1
Location: Westchester, NY
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| Posted: Tue Jul 30, 2013 7:29 pm Post subject: |
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| I recently re-wired my 1968 Berry Mini T. I attempted to make my own, but it became too much of a hassle. I decided to purchase a Painless Wiring product. There are many products to choose from depending what you want to wire. In my opinion, it is worth it and look professional when done. |
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MURZI
Samba Member
Joined: August 25, 2005
Posts: 5066
Location: Madisonville, La
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| Posted: Tue Jul 30, 2013 7:51 pm Post subject: |
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Pretty easy.....
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EVfun 
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Joined: April 01, 2012
Posts: 6276
Location: Seattle
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| Posted: Tue Jul 30, 2013 8:58 pm Post subject: |
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I roll my own. My buggy rolled for many years with a simple 2 fuse harness roughly based on a 1964 Bug harness. I'll be building another one for my mini-t.
You will notice the red wires connecting the battery, starter, and generator, then going forward to the light switch, then off of the fuse block back to the ignition switch. At the back of the buggy, after the starter, batter and generator connections, I run the red wire to a 2 fuse block under the back seat. From there I run one red wire to the ignition switch and one red wire from the other fuse to the light switch. Everything you see connected to the left most fuse in the '64 schematic is connected to the ignition switch output. If you have any of the things shown connected to the right most fuse these are tapped off of the power input to the light switch. The other 6 fuses are all lighting fuses, and in my case not needed because the power input to the light switch is already fused.
If you use a late model light switch you could add a third fuse, as those headlight switches have one power input for running lights and another for head lights.
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| Wildthings wrote: |
| As a general rule, cheap parts are the most expensive parts you can buy. |
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herkster
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Joined: February 14, 2013
Posts: 428
Location: Boca Raton, FL
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Dale M.
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Joined: April 12, 2006
Posts: 20871
Location: Just a tiny bit west of Yosemite Valley
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| Posted: Wed Jul 31, 2013 7:08 am Post subject: |
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Buy a ready made harness.... $150- $250....
Buy bulk wire and parts and terminals.... $150 - $250.....
After wiring at least 4 buggies a 32 Ford roadster, and a 48 Ford Convertible with EFI.... Premade harness (kit) will win every time....
Kits usually have more than enough wire and part to do the job, so you may have leftovers.... Also kits with wire designations printed on wire are a no brainer.... Naked wire with no designation or the tag you put on came off or 5-6 wires with same color are mystery wires that will take extra time to identify...
Kits also take guess work out of what wire size to use for whatever application and come with diagrams and instructions....
Yeah you can roll your own, I do, but you have to buy 6-8 different color of wire (in bulk rolls) and you will need several different gauge (wire size) for different applications, and buy fuse blocks and relays and switches and lamp sockets and push buttons ...
You will have a very expensive relationship with places like Delcity and Waytek wire if you roll your own.... Local FLAPS will kill you financially trying to buy wire and connectors as they cost about 50% more in the small quantities (over bulk buy) you have to buy off their displays....
Only caveat here with a kit is some kits are not intended for rear engine cars and may have some engine control wiring that is to short to fit application... Be sure kit is designed for your application...
Dale
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“Fear The Government That Wants To Take Your Guns"
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lostinbaja
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Joined: December 19, 2004
Posts: 4036
Location: Frankfort, Illinois
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| Posted: Wed Jul 31, 2013 7:26 am Post subject: |
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I always build my own and have never had a breakdown due to wiring.
My flip down fuse/relay panel:
I wired this buggy without a flip down panel:
More home made harness:
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jspbtown
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Joined: January 27, 2004
Posts: 5244
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| Posted: Wed Jul 31, 2013 7:55 am Post subject: |
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lostinbaja......I like that grounding system
I don't think you can do it for much cheaper than a Rebel kit. Plus they offer good technical service. I just finished my Deserter using a 12 circuit kit from Hot Rod wires. They have very good technical service. Unfortunately I needed to use them because my brain is getting squishy. |
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joescoolcustoms
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Joined: August 08, 2006
Posts: 9054
Location: West By God Virginia
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| Posted: Wed Jul 31, 2013 8:27 am Post subject: |
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Time is the most expensive thing I have. The Rebel harness lets me wire a buggy in a weekend.
The Rebel harness for a Bug is perfect for my buggy builds. Set up for rear engine configuration, all wires labeled (super time saver) and it is plug and go play.
I have bought the cheap wire kits and ended up with more in them than a good harness once everything was done. (relays, additional wire, flasher relay, additional fuses)
I have wired from scratch and it was a PITA keeping everything straight over a few weekends and then trouble shooting before ever leaving the garage.
For my Manx, I will buy the Rebel Delux Beetle kit and have them change a few wires for additional gauges I will be running in it. The little bit of money saved on a buggy project building a wiring harness yourself is very minor once the overall project is totaled up. A pro harness is a asset when selling the buggy later.
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BIGMIKEY
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Joined: September 24, 2007
Posts: 1143
Location: North East Pennsylvania
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| Posted: Wed Jul 31, 2013 9:53 am Post subject: |
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| joescoolcustoms wrote: |
The little bit of money saved on a buggy project building a wiring harness yourself is very minor once the overall project is totaled up. A pro harness is a asset when selling the buggy later. |
This is the key to my thinking as well.
Mike T
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BIGMIKEY
Deserter Series 1 project.
https://www.thesamba.com/vw/forum/viewtopic.php?t=787047&highlight=
1973 Beetle Driver, Marina Blue. |
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Hecubus
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Joined: March 28, 2005
Posts: 206
Location: Calgary Alberta
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| Posted: Thu Aug 01, 2013 9:16 am Post subject: |
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| Just curious from you guys that have already used a Rebel wiring harness. They give three beetle related options. A very basic 4 circuit, a 12 circuit and a 16 circuit. Which ones did you guys use? 4 circuits seems very basic but the jump to 12 and 16 seems like huge overkill for a buggy. Also since these kits are made for a beetle do you also need to add your own grownd wiring? |
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jspbtown
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Joined: January 27, 2004
Posts: 5244
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| Posted: Thu Aug 01, 2013 9:23 am Post subject: |
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I am currently using a Hot Rod kit that is 12 circuits. wiring it per their manual I have two circuits left over. A radio wire and a large 30 amp AC wire. So if you are running a stereo or some heavy lights, or maybe an amp, then this 12 circuit would be just fine.
Yes...I am unaware of any kit that will provide you with the ground wire you need for a buggy. |
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joescoolcustoms
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Joined: August 08, 2006
Posts: 9054
Location: West By God Virginia
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| Posted: Thu Aug 01, 2013 5:55 pm Post subject: |
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I bought the 12 circuit kit. Used all 12. (If I remember, all but two curcuits were pre-wired with 2 as extra auxillary).
No kit I have seen gives a ground circuit. You will need to make a ground buss to complete each circuit with. Not hard at all. Large guage wire to a buss bar. Then smaller wires from buss to each accessory, or one wire to dash and then jumped to each accessory.
My Ground Buss:
_________________
Bad News Racing 2018 NORRA 1000 3rd in Class
Best Day Ever Racing 2022 NORRA 1000 2nd in Class and first All Female team to complete the race
Everyone is gifted. Some just do not open the package.
Looks like it was painted with a live chicken,polished with a brick and buffed with a pine cone |
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herkster
Samba Member
Joined: February 14, 2013
Posts: 428
Location: Boca Raton, FL
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| Posted: Thu Aug 01, 2013 6:21 pm Post subject: |
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| is there a place online to buy what is needed for a bus bar for ground? I have a local electronics shop but they never seem to be open when i can get there... |
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joescoolcustoms
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Joined: August 08, 2006
Posts: 9054
Location: West By God Virginia
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| Posted: Thu Aug 01, 2013 6:33 pm Post subject: |
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I bought mine at Lowe's. It is just a terminal block that I trimmed a thin piece of aluminmum to bridge all the terminals making it all one circuit.
_________________
Bad News Racing 2018 NORRA 1000 3rd in Class
Best Day Ever Racing 2022 NORRA 1000 2nd in Class and first All Female team to complete the race
Everyone is gifted. Some just do not open the package.
Looks like it was painted with a live chicken,polished with a brick and buffed with a pine cone |
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saw2
Samba Member
Joined: November 06, 2008
Posts: 321
Location: nw Oregon
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| Posted: Thu Aug 01, 2013 6:59 pm Post subject: |
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| Almost any online marine parts supply will have a good selection of ground buss bars. |
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Dale M.
Samba Member
Joined: April 12, 2006
Posts: 20871
Location: Just a tiny bit west of Yosemite Valley
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| Posted: Thu Aug 01, 2013 8:05 pm Post subject: |
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Use house AC distribution panel ground bar....
Lowes, Home Despot, Ace or True Value hardware.... Ground is ground....
Little dab of dielectric grease on wire to prevent corrosion, ... Life is good....
Dale
_________________
“Fear The Government That Wants To Take Your Guns"
"Kellison Sand Piper Roadster" For Street & Show.
"Joe Pody Sandrover" Buggy with 2180 for Autocross (Sold)
============================================================
All suggestions and advice are purely my own opinion. You are free to ignore them if you wish ... |
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Roys_Big_Toys
Samba Member
Joined: April 30, 2011
Posts: 225
Location: Richmond, VA
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| Posted: Thu Aug 01, 2013 8:30 pm Post subject: |
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I used the Rebel kit and the flip down aluminum panel, just like LostinBaja. I also attached a 12vdc aux power jack on the bottom that ends up under the radio. I think the Rebel kit works well with the color code and wire markings. I also used lots of spiral wrap (Home Depot, price and selection) and lots of tie wraps.
_________________
I'd rather be an hour early than 5 minutes late. (Mine)
"It's not a hobby, it's an addiction" (My wife)
"Socialism only works in two places: Heaven where they don't need it and hell where they already have it." -Ronald Reagan
Original Meyers Manx
Berrien LKD Warrior Ecotec 2.2 w/ Bus 091 Trans
Original 2 sided Meyers Manx Dealership sign
Meyers Manx Surf Board #1 0f #100
Custom Meyers Manx Cornhole game |
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