Wiring Basics and my completed Tuffy Console Switch Panel

[Randy88FJ62]

I have been running wires in my truck for almost a decade and every few years I had to rewire things as the rats nest got worse. I was done with amateur hour wiring and thought I'd share my novice setup to help others.

I have a Tuffy Console given to me years ago by a fellow club member so I cut out the front and had a plastic switch panel for a few years. I wanted to add more switches and to do that I had to streamline and standardize to all Carling Tech Contura II / III switches. I bought all my stuff through waytekwire since their pricing was pretty cheap.

I used 630 metri-pack terminals which snap into carling connectors. The connectors plug into the back of carling switches.

I used 280 metri-pack terminals which plug into Eaton Cooper Bussmann weatherproof fuse box.

Proper automotive GXL wire was used.

These connectors require special crimpers. I was able to do all crimps using a cheap $28 crimper off amazon. The crimp in the pic is rough, the ones that actually got installed were a lot better. Pull test showed they weren't going anywhere.
Amazon.com: GM Delphi Weatherpack Crimper Tool: Automotive

I used 304 stainless for the switch panel and carling tech switch windows that snap in place. The switch covers are removable and customizable. I put the switch cover in a kiln at 1,000°F for an hour hoping for a bluing effect and got a brownish gold color instead. Very modular and easy to setup. All this was very time consuming but I am happy with the outcome. Built not bought. All the wiring in the center console is controlled by a eaton switchable circuit breaker so I can turn it off or on at any time.

The ugly before mess being ripped out:

Here are the final results:

 

[mattressking]

Looks great! I will recommend to anyone that wants to start doing more wiring to use the following Molex tool, provides a few more options for sizes as well. I've been using this for motorcycle wiring as well and it's excellent. Most of the terminals on our trucks use a 3.9mm spade if I remember correctly.

Molex 63811-1000

 

[mattressking]

duplicate...but cannot delete.

 

[ander42b]

Look good !!!!! But, what did you do with the wiring inside of the console ?????? How did you route the wiring inside of the console so shifting contents would not slam up angaist the wire leads and break the leads from the switchs???? Can you take some pictures of in side of the console.

I'm going to be starting a similar project in the next couple of weeks. I wouldn't have as many switches or buttons but I still want the full use of console. Because I have two teenagers who like to throw there stuff in the console and run. Thanks Jason.

 

[Randy88FJ62]

The console I own has a divider up front which I assume was to separate the radio head unit from the larger cargo area. I cut a hole in the middle of the barrier to bolt in a fuse panel.

Regarding the routing of wires. I drilled two holes on either side in the front section, added 1/4" wire loom on the edges of the holes to prevent cuts, and rain the wires in that way. All seating wires come in on their sides and the dash or firewall wiring can come in from their door OEM looms or straight down the transmission hump and in.

It all depends on the console you have.

I also bolted a small metal box to the bottom where the rear heater used to be and mounted a removable lid. I can access the ham radio transceiver if needed and hide other wiring.

Pics will make this clear but I am still at work.