Rewiring an s30

I hate wiring.

Maybe that isn’t exactly what I mean.  Allow me to explain.  If I could be 100% sure that electricity would behave as intended, I’d love wiring.  Unfortunately, cold solders don’t give any indication that they’re causing a problem until you put power through them.  Incorrectly grounded circuits mysteriously fail, only giving feedback when you dig the multimeter out of the bottom of your toolbox, find a new battery (because the old one died since I last used it), and start poking around for the problem.

A better way to rephrase my initial statement is:

I hate trying to diagnose electrical issues that I didn’t cause even more than those that I caused by my own hand.

The main circuit powers my switch panel, and nothing more.  Each power switch controls the power to a circuit.  Each control switch operates the controls for that circuit.  After every switch is an LED indicator light (so I don’t have to go around with a test light after something fails, and because lights are pretty).  From there, a fused relay will be triggered and the circuit component will receive power.

The most difficult part of rewiring was figuring out what actually needed to be re-engineered and what could stay as-is.

My power circuits are:

  1. Master (switch panel)
  2. Fuel pump
  3. Ignition coil
  4. Starter
  5. Radiator fan
  6. Accessories (alternator trigger, running lights, gauges, etc)

My control circuits are:

  1. night-time lights (high/low)
  2. directionals (l/r)
  3. horn
  4. wipers (high/low)

The relays will be constant-hot, but the switches are shut off when the master switch is flipped.  The relays I purchased were a kit of 10 for $25 and are standard Bosch-style, and I’m using the 87/86/85/30 setup for these.  In my configuration, they will be wired as:

  • 87 — component to receive power
  • 86 — ground
  • 85 — signal
  • 30 — power input

Bosch relays are amazing in the number of ways they can be wired up.  Here’s a great writeup on how they work, and how you can make them work for you: http://www.bcae1.com/relays.htm

About the Author

Jesse
Efficiency, performance, and safety. Everything else is excess.