Full Wiring Harness Swap, any tips?

[Pacmanfever]

The wiring in my son's 67 is spliced poorly in many places from previous owners, and we've had a long suffering short that is frying the wires going to the ignition switch, so the bus isn't runnning now.

Part of me wants to be done with the ugly wiring and install a new harness throughout, but I know that has its own perils.

I install harnesses on a different type of machine almost every day at work, so I'm comfortable with the process, but they're not the same as a bus.

Any tips or cautions from those of you that have done a replacement? Best places to buy? What to avoid?

[ryans65]

Its a lot less daunting once you have the old harness out and start running the new one. Just follow the wiring diagram supplied and you should be able to knock it out in a day.

[nlorntson]

Toss in an inline 8A fuse for the parking lights (gray wire feeding the left and right headlights.) That seems to be a common problem for buses resulting in a lot of smoke and a fried wire from the headlight to the light switch

[Skim]

I bought a new harness from Wolfsburg West and it was pretty easy. I enlarged the hole slightly with a Uni Bit where the harness goes up into the nose from underneath, made life much easier. I taped the harness up really tight with electrical tape to make it pass thru all the tight spots easier. I cut my old harness midway along the frame rail then tightly taped the front of the new harness to the back of where I cut the old one and pulled it through using the old harness to tug, then repeated the same for the back of the harness.
After that I just followed the diagram and connected everything.
I did the same method on the dome light harness. Taped it to the old harness and pulled it through. Taping it to a coat hanger also helps if necessary.
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GFK
Samba since before the towers collapsed. Still here.
1953 Kabriolet
1954 Sunroof
1959 Lowlight Ghia vert
1960 Lt Grey Double Cab SMZ LEGIT
1963 Deluxe Turkis Walk Thru 15 Window OG Paint

[azbob]

I actually enjoyed doing this one. Print the diagram and laminate it, Staples will do both in large enough format. Make sure not to pull the old one out w/o bailing wire, fish tape or the new harness attached (securely) to it. I helped a friend run a new harness through w/o having anything to fish it through with. It had belly pans and was a bitch.
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Bus Builder

[turkis-deluxe]

I just did a complete wiring harness on my 62 crew cab and bought it direct from Wiring Works. If you spend the time to do everything correctly including cleaning and replacing all ground connections, cleaning all your switches connection points and soldering the fuse block you should never have anything to worry about. It's a ton of time doing everything correctly especially if you're doing it by yourself but the results will be amazing!!! I finally have one of my buses where everything works properly.....

[crofty]

[EeVeeWee]

I bought a new wiring harness for my 1967 bus at VWlooms.com and was very satisfied with the quality.
You als get a correct wiring diagram with it.
It was fitting well and every connector also was soldered, so very good quality.
When you have questions during the fitting, a guy named Jon Aaron answers your questions in a reasonable time also.

[turkis-deluxe]

[Bruce Amacker]

Remove and bead blast EVERY connector/socket/spade the harness goes to. There's a big difference between doing something and doing something right...….
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'66 Deluxe Bus
'65 Standard Bus
Build threads:
'66- http://www.leakoil.net/forum/viewtopic.php?f=23&t=2888&sid=54d8dedfb3822f99c7f2ea430cb4e856
'65- http://leakoil.net/forum/viewtopic.php?f=23&t=4263

[Malokin Martin]

Cut your old harness about 1/2 foot before the fuse box and at the the other end also. That way the spades and colored wires are left connected and you don’t have to play guesswork. I would still double check they’re right before you turn the key. Also, I’m sure someone above mentioned tying a thin string to the old harness when you pull it out. Threading it back in is easier that way. Also Soldering connections is always a good bonus step.

I’ve had a wiring works harness for somewhere around 5 years and been happy with it. Most places just resell theirs, so may as well buy direct.

[Pacmanfever]

Thanks for all the great tips, I'll follow up and let you know how it went.

Edit: I just ordered from Wiring Works and they've got the full harness on sale for $239.00 with free shipping.

Bonus time!

[hitest]

I recently installed a Wiring Works harness following a full repaint- that meant the old harness was pulled several years ago. It took me about 2-1/2 hours flying solo under my '65 double cab. I used cardboard sheets as back surfing boards and slid around feeding some wire, pulling a little, and so on. I fed fish wires from the front and from the back toward the middle- and fished the harness from the middle outward. I'd never heard of that technique- but I knew while doing it alone it might be the only timely way.
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[DubStyle]

I've been kicking this idea around too. I hope I can use the old harness to pull the new one in, belly pans are my biggest concern.
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Anthony

SBS #1
SBS #1 on FB

"The original & best lowered Split Bus website/club"

[swharris]

Lube!

[aa390392]

Its easy as taking a dump....follow all the above, I did it and am an electrical retard.
Cheers Thomas
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.
getting grumpy & less tolerant!


55 ragtop
56 delux sedan
56 Kabriolet

[Bruce Amacker]

You don't need lube. If you don't run a string, a home style "fish tape" works fine to get it through the framerail. Tape up the wires on each end with masking tape to make a point, that will make it easy to feed. I start in the middle and work out, you'll know when it's forward/backward enough by when the starter wires fit right.

Once it's run, hooking up everything is fairly straightforward, the directions are great. Like I said earlier, the biggest mistake guys make is not cleaning everything properly. I've re-done a lot of bad wiring work in my life.
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'66 Deluxe Bus
'65 Standard Bus
Build threads:
'66- http://www.leakoil.net/forum/viewtopic.php?f=23&t=2888&sid=54d8dedfb3822f99c7f2ea430cb4e856
'65- http://leakoil.net/forum/viewtopic.php?f=23&t=4263

[earlywesty]

[Reedster]

Wiring works
(310)519-8147
2025 S. Mesa St. San Pedro Ca. 90731
I ordered one last week.

[Dubskii]