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Unread 02-21-2011, 10:08 PM   #1
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Default DIY Wiring Harness

i'm building my own wiring harness for lights and such and thought i'd share the progress the community.

i started out with just fog lights, a relay, a switch and a 12v battery. i would eventually like to make the cart street legal so i've since cut in some factory CC front lights and aftermarket LED tail lights. still have to figure out how im going to control everything; blinkers, brake light, etc.

the junction box is made for tractor trailer lights and is via the eBay. quick connect plugs are made from 2x2 15amp anderson power poles. i'll likely do something similar in the rear. most wires were laced, some i twisted. bare wire ends were coated with no-ox-id prior to crimping.

i'll post up some progress as soon as i locate some affordable wire.
-sj
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Unread 02-21-2011, 10:38 PM   #2
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Default Re: DIY Wiring Harness

I saw a cool looking brake light switch on ebay, check it out: Item 130487419748

Here's a wiring diagram for a standard signal/brake light system:

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Unread 02-21-2011, 10:46 PM   #3
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Default Re: DIY Wiring Harness



With the leads this short, will you be able to replace a burned out bulb in the future without removing the entire cowl? Just a thought....
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Unread 02-22-2011, 12:37 AM   #4
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Default Re: DIY Wiring Harness

Quote:
Originally Posted by dougmcp View Post
I saw a cool looking brake light switch on ebay, check it out: Item 130487419748

Here's a wiring diagram for a standard signal/brake light system:
that is a neat switch...

is the stock club car switch any good?

i've seen that diagram before.... i take it thats a 8-wire switch? i see a lot of 7 wire universal turn signal/brake switches available. i've also seen one that mentions its for LED use. not sure if that was just the flasher or the switch. i know some flashers don't like the smaller load of the LEDs and will flash fast like a bulb is out. i gotta do some reading...

Quote:
Originally Posted by gornoman View Post
With the leads this short, will you be able to replace a burned out bulb in the future without removing the entire cowl? Just a thought....
i don't think it'll be a problem... i left the factory spades intact. it all pulls apart quite easily.
-sj
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Unread 02-22-2011, 03:15 AM   #5
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Default Re: DIY Wiring Harness

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Originally Posted by sonicj View Post
i've also seen one that mentions its for LED use. not sure if that was just the flasher or the switch. i know some flashers don't like the smaller load of the LEDs and will flash fast like a bulb is out. i gotta do some reading...
The only difference is the flasher. If you use the regular flasher you can install a resistor in series with one bulb on each side to simulate the load.
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Unread 02-22-2011, 01:24 PM   #6
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Default Re: DIY Wiring Harness

Hmmm. Hey dougmcp, wouldn't the resistor have to be in parallel with the led to simulate the bulb current draw? Just askin'.
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Unread 02-22-2011, 01:29 PM   #7
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Default Re: DIY Wiring Harness

Sorry Roger, I wasn't thinking, you are correct.
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Unread 02-22-2011, 01:35 PM   #8
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Default Re: DIY Wiring Harness

Ok dougmcp, for a minute there, I thought my basic electical theory had "shorted out".Haha.
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Unread 02-22-2011, 01:57 PM   #9
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Default Re: DIY Wiring Harness

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Originally Posted by rogerthedodger View Post
Ok dougmcp, for a minute there, I thought my basic electical theory had "shorted out".Haha.
With my background in electrical engineering, I should be contemplating turning in my certificate. Sometimes multitasking and old age don't mix.
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Unread 02-26-2011, 03:53 PM   #10
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Default Re: DIY Wiring Harness

just ordered a grote 48282. hopefully it'll work out aight! i'm planning to use the pull to dim switch to toggle the headlights on and off.

everything is wired up.... now i get to play the waiting game. ugh!
-sj
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