Wiring harness replacement for End-of-Life Cars

greenhorn · 7th June 2023, 18:54

Hi all,
My Indica's share of problems has begun to skew towards electrical as I keep replacing or overhauling key mechanical and cosmetic components, but I am still stuck with my 15 year old wiring harnesses. My electrician has done a bunch of tactical fixes by doing point to point wiring and using direct lines and relays driven by the original wires which are going high resistance.

Most of the original wiring harness connecters have been corroded to disintegration, and with so many splices and duct tape, I'm seeing electrical reliability going for a toss, particularly my brake, indicator and reverse lights which keep failing all the time.

I just dumped 8K into a floor wiring harness, and am hoping boodmo will be able to source it, but I don't know how many of these issues will get solved by this. There are other wiring harnesses which simply are not available in the aftermarket - How do people work around this when doing full overhauls ? I guess point to point wiring is the worst case situation, but I'm not sure how reliable/troubleshootable/Plug and play they'll be. Are there any better options? does anyone make custom wiring harnesses? especially for non global models like my indica.

GTO · 8th June 2023, 08:08

When I rebuilt my Classic 4x4 in 2010, it was a model long out of production. We used a brand-new wiring harness from a Mahindra Major and altered it to suit our needs.

Hope you're able to source it through Boodmo. Also search for the wiring harness of similar cars (e.g. Indigo, maybe Vista?).

srini1785 · 8th June 2023, 08:30

Quote:

Originally Posted by greenhorn

Are there any better options? does anyone make custom wiring harnesses? especially for non global models like my indica.

Most of the out of production motorcycles have custom built wiring harness. During restoration, the points gets changed to CDI and 6V gives way to 12V. So there is a change in wiring. I'm not sure about cars though. In all possibilities, you need to either build one or scavenge one from a junkyard.

If you know your way around wires, you can build a wiring harness yourself. The connectors, wiring shields, fuses are all available online.

7th June 2023, 18:54	#1
greenhorn Senior - BHPian Join Date: Apr 2007 Location: KL-01 Posts: 7,878 Thanked: 4,910 Times View My Garage	Wiring harness replacement for End-of-Life Cars Hi all, My Indica's share of problems has begun to skew towards electrical as I keep replacing or overhauling key mechanical and cosmetic components, but I am still stuck with my 15 year old wiring harnesses. My electrician has done a bunch of tactical fixes by doing point to point wiring and using direct lines and relays driven by the original wires which are going high resistance. Most of the original wiring harness connecters have been corroded to disintegration, and with so many splices and duct tape, I'm seeing electrical reliability going for a toss, particularly my brake, indicator and reverse lights which keep failing all the time. I just dumped 8K into a floor wiring harness, and am hoping boodmo will be able to source it, but I don't know how many of these issues will get solved by this. There are other wiring harnesses which simply are not available in the aftermarket - How do people work around this when doing full overhauls ? I guess point to point wiring is the worst case situation, but I'm not sure how reliable/troubleshootable/Plug and play they'll be. Are there any better options? does anyone make custom wiring harnesses? especially for non global models like my indica. Last edited by greenhorn : 7th June 2023 at 18:58.
	(7) Thanks

8th June 2023, 08:08	#2
GTO Team-BHP Support Join Date: Feb 2004 Location: Bombay Posts: 71,860 Thanked: 323,037 Times View My Garage	Re: Wiring harness replacement for End-of-Life Cars When I rebuilt my Classic 4x4 in 2010, it was a model long out of production. We used a brand-new wiring harness from a Mahindra Major and altered it to suit our needs. Hope you're able to source it through Boodmo. Also search for the wiring harness of similar cars (e.g. Indigo, maybe Vista?).
	(6) Thanks