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Wire Your Buggy
By
David Helland - Club Member #50
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I changed the fuse block to a current automotive ATC "spade" type
with ten positions rather than the original eight. The extra fuses
I used for secondary power to the radio and cigarette lighter. I
used two - five position fuse blocks (available at Kragen or Pep
Boys) for a total of ten fuses. The AGC type ("glass tube") fuse
blocks can also be used but the ATC type fuses are in much more
abundant supply. The easy way to attach the fuse block is to epoxy
a piece of wood to the underside of the hood or backside of your
dash then screw the fuse blocks to the wood. The fuses must be easily
accessible so you might consider mounting the fuse block such that
the fuses stick out through the dash. You will also need to get
the multiple spade lug adapters from Pep Boys to turn one spade
lug into two. You will need these to connect more than one wire
to positions on the fuse block. It is not a good idea to crimp multiple
wires into a single spade connector.
To form the wiring harness I epoxied plastic tie strap hold down
blocks along the width of the hood. You could also epoxy pieces
of metal "plumber's tape" (1/2" wide galvanized metal strap with
holes punched down the center) for this purpose. Before epoxying
anything to the fiberglass, the surface must be ground down to remove
the wax coating left by the top resin coat. I used short pieces
of wire to hold the wires to the tie down blocks until I was nearly
finished and then replaced them with tie straps. Make sure you leave
room for the wiper motor when forming the harness.
It is important to labeling the wires. I labeled wires at both ends
using white plastic labels made from nursery plant identification
sticks. These labels can be purchased at a nursery and you get about
50 for a couple dollars. I cut them into 3 labels each and punched
holes in them. I used small tie straps to connect them to the wires
and a Sharpy Felt pen to write on them. That way the color of the
wire is not important. I did use Red wire for power, Black for ground,
and some yellow and white for low power items (indicator lights
etc.)
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