How To Make a Wire Harness

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How To Make a Wire Harness

Postby Former Member » Tue Feb 24, 2009 9:17 pm

A while back Bighoss asked about measurements and wire guage for the wire harness for the cub with lights. We have the schematics, but we wanted something more "visual"

The harness on rudolph was in good shape but the webbing was getting frayed. I decided to replace it with new, and used a section of red webbing I got from Wisconsoncubman a while back.

So I took some pics and some measurements and here we go.
This first pic is of the total length, with the voltage regulator attached. The old cloth covered wires look to me to be about 10ga? they are quite heavy.
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Here you can see the thickness of the wire
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The length of the heaviest wire was 39". It is the one that goes from the starter to the switch to provide the power. here you can see where it splices thru the loom before the rest of the wires.
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The next 3 wires are a bit smaller, I would think they are 12ga. They are each 45" long
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here in this next pic, you can see on the left where the light wire splices into two smaller ga. wires 14ga I think. the right hand light wire is 9" and the one for the left is 24"
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The next two pics are of my new harness. It is not completed as I need to cut to length and add the correct ends. The new loom is 24" long and the "HOT" wire splices thru it about 7" from the end. I have a conversion van I am going to scrap, and so I took the wire I needed from the overhead wireing which is the heavier 10ga wire. I was able to get white for the lights, blue for the other wires and Red for the "hot" wire.
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I am looking forward to finnishing it up.
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