Routing the Harness - Part I
One of the shortcomings of the AAW instructions is the rather poor harness routing diagram. It leaves much to interpretation. After trying to do what I saw indicated in the instructions for about 2 weekends I had pretty much given up on it and decided to do it my own way. I'm speaking primarily about the under dash part of the harness by the way. This is what I came up with.
I basically brought everything that went under the dash between the wiper motor bracket and my heater box.
- Circuit branch 3, which includes the ignition switch wiring, steering column wiring and miscellaneous stuff like radio leads comes out to the right of the steering columns saddle.
- The instrument cluster wires come through the middle of the saddle
- All other wiring including the head light switch connector, rear body and accessory connections, etc route behind the saddle and emerge to the left of it.
I had made peace with this and was going to proceed like this.
BUT over the week I had a look at the install of this same harness on VMF and I got inspired. So I decided to give it one last go and see if I could get this harness to go where I wanted it to. Additionally I decided to wrap the wires under the dash. I mentioned earlier that I hadn't decided what to do as far as wire wrap goes. Well after examining what's on the market I decided to go with this stuff:
Its split braided looming. This kind is called F6 Techflex, you can buy it at numerous places including McMaster and Ebay.
I bought:
-1"
-1/2"
-1/4"
-1/8"
I'll let you know if the lengths I got were enough or not once I finish the job
.
Some people prefer the regular braided looming over this stuff. I like it too, I've used it for a few other things. It looks really sharp. Unfortunately you have to slide the ENTIRE wire through it. Plus you have to take the pre-assembled connectors off on alot of the wires just to slip it over. Not to mention that branching off from the main harness is alot more difficult than it is with the split version.
So what do you need do this job? Well I'll tell you what I used:
- Weller 8200PK 100W/140W Soldering Gun with cutting tip
- Heat Gun
- Heat Shrink
- Friction Tape
- Various tools like scissors and cutters and zip ties come in handy too
I used the Soldering Gun to cut the loom that way I didn't have to deal with fraid ends. Of course you can do whatever you want to cut it. I used the heat shrink over the ends of the loom where I could to close the ends. If it was impossible to use heat shrink I used friction tape, which I bought from Lowe's. Here is a picture of my supplies:
Also pictured is a nifty label make I just happened to have. You don't really need it but it comes it handy. Since I was wrapping alot of the wires up to the point where I could not read their labels, I decided to label the ones that weren't particularly distinct, at least until they are hooked up.
So at what point should you do this? Good question
Since I'm doing a sort of trial and error approach the way I've done it probably isn't the most efficient. I'll go through my steps though and you can decide if you want to do it differently.
Well before I even started thinking about wrapping these wires today I thought I should first see if I can get them where I want to go. Thats what I'll cover first.
In order to clear room in the footwell I elected to route the engine harness and front wiring harness first (Circuits Branches 1 and 2). Another vague part of the AAW instructions is the location of the engine harness. In the routing schematic the only information given is a non-descript "New Engine Hole" notation placed in what kind of looks like the middle of the firewall. I had to give AAW a call and talk with some others on here to find out that yes you have to in fact drill a hole in the center of your firewall, 1" in diameter. If you are following AAWs guidelines that is.
Here is where I put mine.
Yeah I scratched up the paint :-\
They apply the grommet for the hole too. It would probably be wise to wrap this branch now in the wire loom. I haven't done it yet because I already routed it before I had the idea for going all out on the wrapping job.
Next you'll want to route the Circuit Branch 2, the front lighting harness. This goes though the existing hole in the firewall just below the brake master cylinder. How you route this branch from fusebox to hole is pretty much up to you. I don't think I have a good picture but essentially what I did was to route it over the steering column and then through the firewall hole. Once again it would probably be a good idea to wrap this branch as you route it, unlike me
Spoiler! I have some wire loom on this branch!
Hmm this is getting long and I'm getting tired. I think I'm going to have to split this into two parts. I'll stop here and continue tomorrow. Oh and here is a picture of my car