Triumphrat

SlowPocono · 11-20-2009, 08:16 AM

I'm delighted that I have been able to get my old original melted and burned wiring harness to work perfectly. As poor as the overall condition of this wiring is I expect it will develop more problems and it needs to be replaced. A new harness is very available but it won't be cheap. The prices I have seen are between $150 and $250 depending on construction. It appears that British Wiring can provide bulk wire in the proper colour to duplicate an original harness. If my calculations are correct all the wire and connectors needed should cost less than $70. Since the original harness is here to provide a pattern I'd like to try building my own.

Is there something I'm overlooking that makes this a bad idea?

Caulky · 11-20-2009, 08:55 AM

The easiest way to make a wiring loom/harness is to use a nail board.
Offer up the old harness to board, knock nails in where there are junctions and ends.
To begin, wrap a wire around one of its 'ends', follow the bends to its other terminal and wrap it round its other terminal nail.
You may need to stick identifying labels (masking tape) ie Rbr Sw...Rear Br Lt, and its colour/s and marks on the board.
This ensures you have adequate wire lengths.
When finished, check it with your wiring diagram, tick-off all wires as you go.
Then tape it up when you`re sure its OK.
I would fit appropriate connectors when its on the bike, cut to length.
Then you can go into production

Rochdale Cowboy · 11-20-2009, 04:26 PM

Whilst there is a profit made by the manufacturers of the harnesses you have researched, I'd buy the best I could as it's nearly a full strip down to fit.
The reason being is that almost anyone will be able to get from battery to light switch etc. without breaking the wire, but the real issue with harnesses is the installation of it. Any quality of harness can be installed so that it is clear of sharp edges and does not foul the steering, but also depending on the patience of the fitter, can be an instant fire risk.
With a quality harness, it should have all the correct connectors and protection over vulnerable runs and a shape to it that leads you to a comfortable installation.
I'd allow 5 hours design, prep and manufacture, then the same again to fit and terminate the interconnects. Allow $75 of tooling too.
You'll have done all this hard work and have to hide it.
Spend your precious time doing something that you can be happier with.
Just my opinion, of course.
No, I don't have a sideline in harness manufacture!

Good Luck RC

GrandPaulZ · 11-20-2009, 04:53 PM

5 hours to design, prep, fabricate & install a complete wiring harness?

HA HA HA HA HA HA ! ! ! !

HO HO HO ....

HE HEE !!!!!

Good luck!

It takes me every bit of 12 hours to hand-wire a Triumph Bonneville or Norton Commando, and that doesn't include additional trips to the parts store to buy more connectors, tape, zip ties & such.

...and I've been doing this for 20 years!

(maybe I'm just getting old & slow...)

SlowPocono · 11-20-2009, 05:44 PM

Quote:

Originally Posted by GrandPaulZ

...

HA HA HA HA HA HA ! ! ! !

HO HO HO ....

HE HEE !!!!!

...

(maybe I'm just getting old & slow...)

That's a lot of laughter over a two hour difference. You are getting old but you may also be getting faster if I read your other posts correctly.

Since you spend 12 hours rewiring bikes should I infer that you think it's a good idea for me to put together my own harness?

Or not?

GrandPaulZ · 11-20-2009, 06:40 PM

5 hours is a bit over 1/2 day, 12 hours is closer to two days.

Anyway, I build my own harnesses for my own bikes, I install pre-fab aftermarket harnesses for client bikes in 90% of the cases, sometimes they are okay with "minimalist" wiring. Cost is about the same, because I charge too little for my time on restorations.

It just sounds so easy going in fresh; check back in when you're done and let's see the "tale of the tape".

I swear, I figure 8 hours and it takes me 12. Don't know why, it shouldn't, but it just does; and that doesn't include design and setup, that's already done and perfected in AutoCad.

RidingDonkeys · 11-20-2009, 06:44 PM

SlowPocono, I would buy the harness. I'm no Triumph expert, but I've built countless wiring harnesses over my days. My job often requires me to expediently fabricate and repair electrical parts. For my money, $100 is worth forgoing the trouble and getting one prebuilt and sturdy.

But if you insist on building it, Caulky's recommendation on a nail board is good as gold. It's the easiest way of doing it.

Keep in mind though, your version will likely never be as clean, sturdy, and streamline as a factory made one.

Coroja · 11-20-2009, 07:34 PM

Hey, if you want to do it yourself, then the time and effort involved doesn't matter! What's the worst-case scenario? You spend $100 on materials (it always costs more), spend a lot of time, and then aren't satisfied with the result. So you spend $200 - $300 (it always costs more) for a complete harness, install it, and the job is done. Maximum downside exposure is approximately $300 and a lot of your time. If you have the time and money, go for it.

On the other hand, the best case scenario will save you $180 (your figures) for an investment of 5 - 6 hours (i.e. a Saturday or most of a week of evenings). If time is laying heavy on your hands and money is tight, that may be the way to go.

Over in England, there is a fellow that does custom bike wiring looms under the name, Ferrets Custom Electrickery. He comes to you in a van with all the wiring, connectors, etc. It takes him the best part of a day to rewire a classic bike. That is about 1/3 the time it took me when I tried it, of course he doesn't spend much time yelling and swearing. Just sayin'....

SlowPocono · 11-20-2009, 08:14 PM

Quote:

Originally Posted by GrandPaulZ

5 hours is a bit over 1/2 day, 12 hours is closer to two days.

Anyway, I build my own harnesses for my own bikes, I install pre-fab aftermarket harnesses for client bikes in 90% of the cases, sometimes they are okay with "minimalist" wiring. Cost is about the same, because I charge too little for my time on restorations.

It just sounds so easy going in fresh; check back in when you're done and let's see the "tale of the tape".

I swear, I figure 8 hours and it takes me 12. Don't know why, it shouldn't, but it just does; and that doesn't include design and setup, that's already done and perfected in AutoCad.

On my computer Rochdale Cowboy stated it would take 10 hours.

But, back to the point, I don't think it sounds easy. That's why I'm soliciting opinions and advice. I'm willing to invest the time. If I wasn't, I'd just by a perfect bike from you and ride it until it broke and then buy another one. I have great respect for your experience and your willingness to help everyone.

RidingDonkeys suggested that my custom made harness would be inferior to a factory made unit and that is something that troubles me. My current harness works perfectly. The only reason I'm replacing it is to avoid future problems. If doing it myself will yield second rate results then I think it would be a mistake to pursue that route. I actually imagined that I would be making a better, more perfect fitting harness than the store bought one.

Remember, I'm not starting from scratch. I have the original harness as a pattern.

I'm not committed to either approach, in fact Coroja's suggestion makes sense. Build my own and then buy a real one when it doesn't work.

If the consensus is that a home rolled harness can't be as good as a factory job I'll save the expense of experimenting and just order a new one.

Are you willing to render an opinion on that?

RidingDonkeys · 11-20-2009, 09:01 PM

SlowPocono, I think I kind of misunderstood where you were coming from. I'll try again.

If you want to build it, then build it. It'll be a great opportunity to learn something.

I've got two basket cases awaiting my return to the States to build bobbers. I've never built a bike before, and I'm convinced this is going to be one heck of a learning experience. I'm doing it for no other reason than I want to learn, and I think it will be fun. They won't be as good as any of GrandPaulZ's bikes, but they will be mine, and I'll have the satisfaction of having done it myself. That's what matters to me.

Can you build a harness better than factory? Absolutely! But to get it perfect will take some patience and practice, especially if you've not done it before.

I do electronics and communcations equipment for the Army Special Ops guys. They are really rough on equipment, and break things constantly. I prefer to build my own cables and harnesses because I build them better and more robust than they come from the factory. But if stuff never broke, I wouldn't know how to make it better. In the end, I learn more about the equipment by building the stuff myself than by ordering parts from the manufacturer.

The same could be said for your situation. If you want a quick and easy fix, buy factory. But if you want a learning experience, do it yourself. Take your current harness off and examine it. Find the wear points and inferior connectors. Look at what's melted too. These are all opportunities to improve upon the design.

If you're in this to learn, GO FOR IT!