What could possiblly be the problem?

[bigtim]

Recently purchased a 73 Super Beetle and the previous owner made some maintenance decisions I did not like. So, I was in the shop looking forward to changing the oil, air filter and removing a large metal fuel filter that I thought was too close to the coil and getting to know my new friend. But first I wanted to warm up the oil and let it cool while doing other things.

Good plans went bad when I looked back and noticed white smoke, quickly turned it off asked the wife what happened and she pointed at the coil, that is when I found a very toasted but not completely melted wire but only one which I guess is a good thing.Aafter searching and probing with a VOM I Ran a new wire up to the front as a test and tied into the large red wire just under the right side of the steering column at the advise of a fellow shade tree neighbor.

Have to confessed I'm not very good with auto electrical but started doing what I know. The bug will start using the key but had to wire in a toggle switch to turn in off. Some of the things running through the ignition switch work but some don't could it be that the short only got one side of the switch and what about things in between? And ideas, suggestions on how to proceed, I really don't want to set the car or my garage on fire.

I'm stumped? Thanks in advance !!

[Cusser]

1. Run a new wire from the trunk to the coil terminal #15
2. Install an inline fuse, like about 15 amps between the fuse box and that wire you ran in Step #1.
3. Also likely that you'll need a new electrical portion of the ignition switch. Don't connect that with crimp type butt connectors under the dash, run them through to their attachment points in the trunk.
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[vamram]

Quick correction - '73 Super has a curved windshield, fuse panel is inside, not in the trunk. Replace "in the trunk" with "under the dash center"....
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[ashman40]

Follow Cusser's advice above.
From the sounds of it, you melted your #15 ignition coil wire. This wire is not fused from the factory. If you ground it at any point with the ignition switch ON it will heat up and quickly melt the insulation.

The other end of this black wire should be at fuse #11 or #12 in your fuse box. Check if the black wire here is also melted.
One of the wires from this same side of fuse #11 or #12 runs to the ignition switch. This ignition switch wire powers both fuses as well as the ignition coil. Check if this wire is also melted. Look under the steering column for the ignition switch plug. One of the wires here will be solid black. This is other other end of the black ignition switch wire at the fuse box. Is this wire melted here? If it is, there is a good chance the ignition switch is internally damaged as well. Such is what happens when you short the ignition coil wire.

Test this black wire at the bottom of the steering column. If there is 12v on this wire when the ignition switch is both in the ON/RUN and START positions you may be in luck. You may only need to replace the wire from the ignition switch plug to the fuse box.
If the ignition switch works but the voltage is always low... you may be able to get by adding a relay into the ignition switch wire just before it reaches the fuse box. Bosch-style SPST or SPDT relays will work with as little as 6v to switch a full 12v from the battery.
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AshMan40
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'67 Beetle #1 {project car that never made it to the road }
'75 Beetle 1200LS (RHD Japan model) {junked due to frame rot}
'67 Beetle #2 {2019 project car - Wish me luck!}

[Cusser]

[bigtim]

Thanks everyone appreciate you taking the time to reply...all good stuff. Now I need to get my head stuck back into this and see what's up. I will get back to you in a couple days and let you know how it went.

Thanks again!!!