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....Simplified?

Was emailing this to a friend and thought I'd put it up here, would love to hear other folks methods ideas.. Maybe I'm doing it the hard way(wouldn't be a first)

I've had this idea to help with layout and putting together wiring, but just never could put the brakes on my working long enough to actually do it.. Well, finally did and it worked very very well..

Isn't for everyone but there must be a few folks around here who find themselves putting together a custom harness, for A/C or D/C conversions and the like..


Pics coming..
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Here the idea.. Make a simple wood board as a jig, the board here was
actually just held up to the frame and roughly traced. Then the wires
can be laid out in correct lengths and 'tacked' together with
electrical tape. Most areas can be shrink tubed, but if you want to
heat shrink the whole thing you would need to start with shrink tube
in certain areas and thread wires thru, like between the rear brake
switch and horn.

Holes are drill in some blocks to sort of hold the wire for those
certain areas. I just threw the jig together thinking I would make any
needed change/adjustments, but it's as perfect as I would need.

Next time I do one, the flip side of the jig board will be for smallies

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Molto Verboso
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Molto Verboso
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Hello

I used to make wiring harnesses as part of my career working with the UK national broadcaster.
Very similar to the Professor just the board was raised on blocks and had lacing pins in to allow for bends etc.
The board has holes in it to allow for terminations etc.
The wire were held together with lacing cord (no zip ties then).


Regards


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that looks more efficient than what i did (shove a mess of wires through the frame and sort it out as needed)....a world before zip ties? thats scary.
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Very nice. I normally just tape the pattern out on the floor.

Unwaxed dental floss works well for holding the wires together until the housing is slipped over and adds almost no bulk.
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So where are you fellas sourcing your bulk wiring?
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Molto Verboso
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I order from Mcmaster-Carr. 300 volt, 18 gauge.

http://www.mcmaster.com/#electrical-lead-wire/=ah6wht

It used to be a business supplier, but has been selling direct to the public for a while. The website can be awkward, and not as easy to navigate as some. They have almost anything, and their paper catalog is absolutely amazing to study. Shipping is fast.
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I go Here:
http://www.wiringproducts.com

and here:
http://www.delcity.net/

The clear shrink tube is, as the kid say, 'da bomb' for terminal ends, adhesive and thick. Cheapest @ delcity..

When doing 12v DC I tend to be a snob and go with 18ga SLX wire.. But really 18 or 20ga basic PVC automotive is fine for scooters.. The SLX is really overkill and best for stators.

For terminals I used to use those "Krimpa-seal" type, but now I hate them. I would rather crimp&solder bare terminals and use the clear adhesive shrink..

For stock look Vintage everyone knows this place:
http://www.vintageconnections.com/
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Professor Plum wrote:

External inline image provided by member with no explanatory text

Is the gray thing in the upper right hand corner a keyed switch?
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Die_Wespe_Kind wrote:
Is the gray thing in the upper right hand corner a keyed switch?
Yup! Only used on the '74 Rally 200 as far as I know.
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Molto Verboso
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Professor, those are VERY good links to electrical suppliers. Bookmarked.
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blackbart wrote:
I order from Mcmaster-Carr. 300 volt, 18 gauge.

http://www.mcmaster.com/#electrical-lead-wire/=ah6wht

It used to be a business supplier, but has been selling direct to the public for a while. The website can be awkward, and not as easy to navigate as some. They have almost anything, and their paper catalog is absolutely amazing to study. Shipping is fast.
i can definitely vouch for McMaster Carr. I have used them in the past when building custom sized powder coating ovens. They work much better if you pick the products online or have an idea at least and then just call them.

waxed wire tie works really well. im an aviation electrician and we use waxed "spot tie" all the time in my line of work. Adel Clamps also make for a very nice install.
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a not so normal vbb2 '64, a weirdo vbx '86, a not so normal pts100 '82 and a yellow sunshine '74 sprint
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thats perfect..
i honour the wires but what fascinating me the most is how clean u paint ur bike evem under the tank as i never gave paint under there but spray it with anti rust formula and look ugly no where compare ur profesional restoration

i love this forum as more and more i learn tons of things and earn more inspiration

mant thanks and cheer guys
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