TI tidy seventeen: lots and lots of wires

Last Saturday I spent 8 hours at the shop working on the wiring harness of the TI.  Yesterday I spent 2 more.  This afternoon I will probably spend another 2 and this coming Saturday another 5 or so.  That’s a lot of time.  More than some people I know, with more cars, tools, and free time than me spend in a season on their cars.  I could have probably made do with about 4 hours of wiring but I wanted it to be somewhat right, as in colors matching the diagrams, connectors insulated and of the original type and splices accomplished with soldering or butt connectors and heat shrink.   It went something like this:

wiring toolsThis is a TI diagram for my car that I colored in with pens etc.  Jim Neill (papajam for you BB’ers) sent me PDF’s of this diagram in black and white and a Super diagram in color.  It would have been great if I had thought to ask before I did the first 8 hour stint, but I didn’t.  The first 8 hours I used a diagram in the back of an ‘all 4 cylinder models’ type manual that had a font size of about 2 and was in Italian to boot.  I needed both diagrams because I am converting to Super dash and switches, not because it’s cool, I just don’t have a TI dash. Anyone have a 64 TI dash to donate or sell?

old style wiringThis area behind the left side headlight and turn signal is a good example of where I started.  Undercoating applied over bundled wires full of zip ties and heavily wrapped in electrical tape whose glue was the color and consistency of molasses but way more difficult to wash off my hands.  Under the electrical tape were ‘twist and tape’ splices going from color to color with impunity.

At 8am on Saturday morning I started with the right side headlight harness for lack of a better idea.  I unplugged all the lights, cut off all the zip ties and wire, cut out all the splices and made new ends in the correct per the harness colors with pieces of my donor harness.  From there I started working toward the fuse box.  As I went I traced wires, labeled them on masking tape at either end and basically cut out anything incorrect.

wiring by productsIf I was a butcher this would go in the Hot Dogs.  This pile of crap is from the headlights back to the fuse box.  I cut the tape off with a razor blade carefully aimed away from my fingers.

rt hd lt wiringHere is the right headlight area after surgury.  All the colors are per the diagram except that little bit of green inside a black insulator with some blue heat shrink going to  a brown wire from the high beam light.  I converted to a set of Bosch inner lights from a Mercedes I had laying around and the original connectors wouldn’t work.  When the whole job is done and I have verified functionality I will unplug all this and get the wires inside insulator sheathing.

lt hd lt wiringThe right side headlight wires meeting up with the left side.  All grounds were connected and cleaned.  A lot of the spade connectors were loose so I squished them with pliers so they would grab better.

firewall lt wiringHere is the fuse box.  Again, all wires labeled where not obvious, all splices removed, all colors per the diagram.  Note horn relay on the valve cover.

dash and wiringI failed to take a picture of this area after wire tracing but before dash installation.  It was a lot of climbing in and out of the car in 90+ degree heat, running extension test leads to far away components to identify all the wires but all it takes is time, determination and cold beer.  Here all the wires to the gauges are hooked up.  Even the fuel reserve light and ventilation fan indicator lights are hooked up.  What you see hanging down is the wired up switches.  Still need to work on the routing and dash in this area.

dash and wiring twoFrom the other side.  I need an AM/FM blaupunkt or Becker, a clock, a shift knob, some ducting between the heater box and defrost vents, some shift boots and, well, you get the idea, lots of stuff.

switchesA close up of the switches.  The red wire along side the steering column goes to the horn relay.  The two disconnected red wires are actually red/black wires and have no place in the harness but I am leaving them for fog lights any other accessory I decide to go with since they are bundled in the harness pretty well and terminate with lots of length in the engine compartment.

What is left to do that is going to take 6 hours you ask?  Well, I’m going to finish installing these switches, make a bracket to hold the ignition switch in the void next to the steering column where a Super usually has it’s switch, wire up the alternator and horn with relay, hook up the battery and start installing fuses one at a time.  When I have verified functionality and a lack of shorts I will use insulating sheathing and zip ties to bundle the branches of the harness sensibly and declare it done.  Well, not done, I still haven’t checked if all my bulbs work, but that’s dessert.

TI Tidy eighteen.
TI Tidy sixteen.


3 thoughts on “TI tidy seventeen: lots and lots of wires

  1. Matt, kudos to you for going to the extra effort to take the wiring harness back to their original colors.

    You should sign your work somewhere on the harness, so future owners will know to thank you.

    I had a car once where the previous owner had apparently gotten a helluva deal on black wire, as he’d replaced pretty much everything under the hood with that, without any labels and regardless of original insulation color. This Goth approach made troubleshooting the electrics an absolute nightmare.


  2. Three alfa re-wiring sessions similar to Matt’s and all I can say is that if it weren’t for Jim Neill we would all be up shite’s crick.

    Nice wiring.


  3. Hey Matt,
    You have the virus bad…When you first hook the whole thing to the live battery, use a testlead jumper with a 30 amp FUSE in the line instead of a direct battery connection. Then test every circuit and combo of circuits except the cranking motor (starter). Your crank may then be less exciting, to use a pun.

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