Truck Wiring Tips


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Golden Jubilee
Golden Jubilee

Posts: 461

Joined: Mon Sep 07, 2015 11:14 am

Post Thu Dec 19, 2019 8:16 pm

Truck Wiring Tips

I have noticed some poorly done wiring installations at truck shows.
Even an IHC rat rod should have a well done electrical system.
Thought I would offer some tips for a cleaner installation and also help prevent
costly fires.

What I notice:
The use of electrical tape improperly , using ty-wraps and cable cover normally
for home stereo equipment and velcro makes me cringe , heres why:


and I know that is why there are auto electric shops but with a little thought and some simple tips
you can make it look neat, with all due respect to those who know and want too know ,
allow me to offer some suggestions ,

By way of:
Using correct terminals sized to the wire gauge, proper wire terminations and routing
, grouping and lacing , wire numbers ect can add a neat touch.
Use of the proper crimps and the tool is a must!

✔ Not all electrical tapes is the same ! Quite to the contrary.
Top grade electrical plastic and friction tapes are the only way to go.

✔ Next ditch the ty-wraps IH has
per installed clips down low on the inter-bay fenders and fire wall..

Seen in the photos:
As the cable bundle comes out the firewall grommet the hole and sleeve the bundle with rubber
then apply tape tightly using your thumb to tightly lay the tape down. I use my wire snips to cut the tape
cleanly, as the last wraps will not stay tight if you pull and snap to break the tape off. Also you can
cut short pieces of tape to layer over sections to get good coverage.
The electrical tape will conform nicely when wrapped with this method.
Tight uniformed wraps are the trick..

Image

Wiring should be routed as discreet as possible.

Image

Some like to tin the connections , but not necessary
as in the case at the voltage regulator , that has slip fits made to land the correct size
fork terminals , these regulator terminal screws can accept ether lugged or un-luged
wire ends , but proper stripped lengths and fit gives the best look and connection.

I recommend to strip the wire to fit to the shoulder of the crimp sleeve or terminal for
the cleanest fit.
A proper wiring job should lay with what is known as soft loops. Once all is in place
it should be a harnessed fit.
OEM or after market wiring harnesses are fitted similarly on a bench then they just lay
right in place when you get them...

Image
Image
Crimp connections can work on the starter too , I simply prefer mechanical lugs.


1/0 wire from battery to starter.
Image
Image

✔ Notice the flat braided ground strap from the generator frame to the battery terminal.
As well here another braided strap from the engine block to the IHC ground point on the cab to insure
under dash ground connections for lights and sirens. :)

Image

These connections are critical to keep the trucks 6volt system in top order. any voltage
Last edited by Harvey on Tue Dec 24, 2019 7:48 pm, edited 24 times in total.
Thanks for Looking - SM

Golden Jubilee
Golden Jubilee

Posts: 4175

Joined: Thu Nov 29, 2012 9:28 pm

Location: Lyman, IA

Post Thu Dec 19, 2019 8:24 pm

Re: Truck Wiring Tip

I plan on brushing up my wire lacing skills for when I make a harness for my K. 40 years ago or so I had to pass an airframe test that included lacing. Almost a lost art.

AZD

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Golden Jubilee
Golden Jubilee

Posts: 577

Joined: Mon Apr 06, 2015 11:00 pm

Location: SLC, UTAH

Post Sat Dec 21, 2019 9:01 pm

Re: Truck Wiring Tips

I wish my truck looked as nice as yours. But I did make a brand new harness. I crimped and soldered all connections, then wrapped with a non-adhesive vinyl harness tape similar to what was used originally. The terminal block is a custom part I made on a mill using 1/4" fiberglass similar to circuit card material. I built it to accommodate the extra features I had planned such as turn signals, fog lights, reverse lights, etc. It's a bit busy but works perfectly. There is a circuit breaker for the main charging circuit and each branch.

IMG_1068.JPG
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Golden Jubilee
Golden Jubilee

Posts: 461

Joined: Mon Sep 07, 2015 11:14 am

Post Sat Dec 21, 2019 10:20 pm

Re: Truck Wiring Tips

Nice and neat - well done!
Thanks for Looking - SM

Pile of Parts
Pile of Parts

Posts: 32

Joined: Sat Dec 22, 2018 12:30 am

Post Fri Dec 27, 2019 11:40 pm

Re: Truck Wiring Tips

Harvey, great topic on wiring. Your 100 % about the plastic loom that is used on wiring. I repaired more broken wires cause by the loom cutting thru the protective coating than anything else. Detroit Diesel is a perfect example of using loom for the engine harness. Changed a lot injector harness (S60) that would wick engine oil to the injector plug in near the rear of the cylinder head. Sometimes it would even get to the ecm. When they brought out the replacement engine for the S60, the silver painted turd (MBE) it cut thru the wires like nothing. Was always replacing or repair engine harness depending on customers situation that day. Cat built great wiring harness, very rare to repair one of theirs's.

When I look at old vehicles, clean & non tacky looking :t10512: grabs my attention. I like how your wiring to the voltage regulator is clean, heat shrink over the ends, wire numbers, etc. I don't care for the ugly looking connectors at the coil though & the lack of a proper battery hold down. But nobody is perfect, especially me. I know next to nothing about body & paint work.
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Golden Jubilee
Golden Jubilee

Posts: 461

Joined: Mon Sep 07, 2015 11:14 am

Post Sat Dec 28, 2019 1:05 am

Re: Truck Wiring Tips

I don't care for the ugly looking connectors at the coil though & the lack of a proper battery hold down.

spot on about these two items.. that there battery hold down is really half baked, lol

But nobody is perfect

quality over perfection for that very reason,

"Quality is never an accident; it is alway the result of high intention , sincere effort ,
intelligent direction and skillful execution ; it represents the wise choice of many alternatives"
Willa A.Foster

I appreciate a man that pays attention to quality in workmanship ...

Thanks for adding more spark to this conversation.. - sm
Thanks for Looking - SM

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