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December 26, 2023

Final Wiring

The wiring on this car represents the largest departure from factory stock.  This is partially motivated by my opinion that the original wiring design was woefully marginal.  None of these cars attained much age before they experienced some sort of electrical problem.  These often involved faulty ground connections somewhere that were sometimes notoriously hard to trace.  Inadequate fusing and the under-use of relays compounded the problem.  I'm clearly not the only one who thinks this way, since there have been a number of aftermarket products available to improve the electrical systems.  Though they typically did little to improve the grounding system, they did provide additional fuses and relays.

My approach on this car is to install a "Power Module" (PM) that holds quite a few fuses and relays.  It also includes a single-point ground bus for just about all devices on the car.




Circuits from all over the car are routed to the PM.  With all cables run, there are a total of 51 wires for the PM to deal with, including 20 ground wires, and two main power wires from the battery.




The ground and power wires run under the PCB, so have to be separated from the rest, which connect to screw terminals on the topside.




I used these little copper adapters to make the right-angle bend for the power conductors.




Each ground wire got this little ferrule crimped on to make an easier and more secure connection to the ground bus.




Then connected all of the circuit wires and installed fuses, relays, and flasher modules.




Testing has to wait for the Dash install.

The wiring on this car has been by far the most time intensive part of the project.  Design and planning probably dominated actual execution by ten to one, but I hope it pays off at testing time.

Comments to Ed at elhollin1@yahoo.com

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