Re-wire project

[Highpsi]

Here's an update on my re-wiring project.

Got in a bunch of new parts from LMC truck the other day.

New halogen upgrade headlamps, new park lamps, new clear sidemarker lenses, new rear lenses with chrome trim (I was surprised especially with these, they were like $16 a piece and really nice quality) and a bunch of other stuff.

I am finished with going through the rear taillight harness and repairing all the ugly, corroded nasty splices GM uses from the factory. I added more weatherpack connections for ease of rear bumper removal, and if I need to change out the trailer connector too. Added a redundant ground here as well, and there's another ground cable further up the chassis grounding the bed to the chassis now too.


My recent order is here!




Here's the rear harness repaired / re-engineered



These #$%# little connectors are holy hell to get out of the firewall connector with all that "resinlike crap" inside the body of the connector.

But I found various replacement sizes of the terminals at waytek wire supply online. That way I can run brand new wire all the way from the terminals at the firewall to any destination. Look at that black crap on the terminals. It sticks to your fingers and stains it!




More to come... I am rebuilding the engine harness and the front lighting system harness right now.

I added the high power halogen upgrade relay harness too for the headlights needed with aftermarket halogen lights. This pic is before everything was wrapped up and put into the corrugated sleeving.



I'll try to update with more photos as the project comes along. I can't wait to put all the new parts on this weekend!

[19_Chevelle_69]

Great progress so far, keep the pics coming!

[Pontiac1976]

Coming alone nicely. Are the New Halogen upgraded Headlamps, plastic or glass . ( are they lighter then the stock ones )
keep up the good work and the story & pic's

[Highpsi]

Scott, the headlights are glass bodies, and the new bulbs are removeable small halogen bulbs. I didn't buy the "blue" bulbs because somehow having this thing look like a Lexus is coming at you seems just wrong! ;D

The pair cost me about $60



And here's the final photo of the finished headlight harness assy. I used lots of plastic t-junctions and fabricated some keepers that you can slide the junction onto. The harness is retained by a keeper and a little metal braket at the bottom.



I will be routing a 2 guage positive cable to that little red stud to run a good power source over to the driver side of the engine compartment to provide stable power for the lights, cooling fans (later), and 12v source to the firewall connector.

...Hmm.. I sense another pricy upgrade soon in the works. The high output alternator...

Anybody have one of those on your truck?

[Pontiac1976]

That kool Highpsi. I was thinking about getting the four HeadLights system for the truck. But I wanted to have them like that, because the glass takes the heat beater if used more offten. I am still trying to find a four head light set up that has the low beams in the plastic with 55 watts for weight saving for my 1977 car. I have gotten the high beams a long time ago I for get the company name now.

Any way that looks good so far. I see you put a loom on the hood release cable to stop it form wearing going throw the rad support. Question is the relays there set up in pairs or singles. I was just wounding, I hear that pairs is better than singles. Oh what the watts on the new lights. Are they pulling more power to make them work then the fatory ones. keep the posting up really like it so far. Two Thumps up .

[Highpsi]

Hey guys!

I am still alive. It just got REALLY cold here for a month or so, and snowed recently so I was snowmobiling lots!

(ha.. figured i would throw this in for kicks)



I am back at it again. Finishing up some final details in the engine bay now with the custom harness. Its nearly complete and I have to start making sense out of the interior fuse block now for the gauge cluster wiring now.

Here's a quick photo of the driver side fender well. This system has the capacity now for twin electric fans that I robbed out of my Iroc-Z. Heavy duty relays etc..



Each power feed to the firewall incorporates a Maxi fuse. The alternator is fused with a Maxi fuse right to the battery direct as well. More photos of those later, along with details of how I did 3 seperate power sources in various places in the engine bay (as opposed to a pile of ring terminals on that blasted starter!)

[Pontiac1976]

It's coming along nice keep it coming the next part can't wait to see.

Oh speeking of snow I post two pic's of the truck & frame on the trailer in the frame section.

[Highpsi]

So I finally finished up with every last bit of the wiring now. I am sure a few things will come up in a bit before the project is done, but for now I think I can finally breathe. This project was done in conjunction with a new gauge cluster setup of course, found in this post : bowtieguy.proboards33.com/index.cgi?board=InteriorTalk&action=display&thread=1167508729&page=1

Here's a few photos of the rats nest of wires I had to make just for the bulbs, power and ground for the gauges. Each circuit was seperated under the dash from the sender wires for ease of troubleshooting (of course that will never be needed! hehe.. yea sure!)



Here I was running the wires for test length and then cutting and terminating.



I will try to come back later with some photos all around and sum up what I did with the entire truck.