I install painless 18 circuit wire looms on my 40's. Someone on my clubs mailing list actually asked what was needed to wire this up. I figure it might be helpful to the folks here. BTW Waytek wire is a great place to get all kinds of automotive wiring items.
Waytek Wire : Electrical Wiring Supplies & Industrial Products
The painless harness makes it really easy. Every wire is labeled as to where it should go. The instructions are really easy to understand too. It also comes with all the insulated connectors you need, but they are not heat shrink. So I usually buy my own connectors.
List of stuff you need:
- Quality heat shrink butt connectors. Red, blue, and yellow. Lots of them.
- Quality heat shrink female and male spade connectors. Red, blue and yellow. About 15 of each size and gender.
- Quality heat shrink eyelet connectors. Red, blue and yellow.
- Heat gun.
- Quality automatic wire stripper. There are ****py ones out there, the ones that are all plastic where you put the cut end of the wire in the jaws. I can't really describe them and I don't have a picture right now. These things don't work and just make a mess. You want an all metal one that you lay the the wire into sideways. This will save you great deal of time and your hands won't be full of blisters and aching after doing a small amount of work.
- Quality regular wire stripper for the odds and ends.
- Quality ratcheting insulated connector crimper. Time and hand saver. Plus you know the crimp is good and will hold.
- Quality heat shrink in an assortment of diameters and lengths.
- An assortment of rubber grommets
- Tube of silicone
- Quality automotive wire loom in various diameters and lengths, NO ELECTRICAL TAPE.
- A digital multimeter with continuity/resistance test.
- Zip ties that match your wire loom color.
- Fully cushioned metal screw down clamps that fit over the wire looming.
- A CS-130 or CS-144 alternator. If you are going this far, you might as well go all the way and get some real power in your system.
- A decent wiring schematic for your truck, I get mine from the haynes manual.
The process is:
- Put your Painless fuse box down on the floor where you would want it to go in your Cruiser. I usually put mine in the cab on the firewall between the clutch pedal and the drivers side wall. It's a tight fit but it works. Arrange the wires to the places you want them to go in your Cruiser.
- Once you have have the wire routing figured out,
- Cut out the old harness and fuse box.
- Keep the connector pigtails for the switches and lights, label them.
- Mount the fuse box in place and start running the wires, putting it in the wire loom, using the grommets, screw down clamps, zip ties, silicone, heat shrink, butt connectors, etc. as you go as needed
That's pretty much it. The trick is figuring out the odd switches like the hazard and the wiper motor switch. Most of the other stuff is easy to figure out from the schematic. I was able to figure out the wiper motor switch, it is a weird negative positive resistance thing and the 4 wires are black. Leave all these wires there, don't cut them as they go to the motor. I remember at the time I hadn't learned enough on electricity so I had to carefully open and disassemble the wiper switch to figure it out. I then put it all back together. Nowadays I could figure it out with the multimeter using the continuity/resistance test. I can't really give you much more than this because everybody's wiring harness has been butchered by POs, so sometimes you just have to have patience and... just figure it out.