Date: Sat, 19 Mar 2005 04:35:07 EST
Reply-To: THX0001@AOL.COM
Sender: Vanagon Mailing List <vanagon@gerry.vanagon.com>
From: George Goff <THX0001@AOL.COM>
Subject: Re: Replacing driver's door wiring
Content-Type: text/plain; charset="US-ASCII"
In a message dated 3/18/05 5:35:42 PM, ryang@LONDON.COM writes:
<< I'm looking for two things here, any BTDT advice and any suggestions for
materials to use to protect the new wires for the future (other than the stock
rubber boot). >>
Don't discount the original rubber boot. After all, it did provide strain
relief for 200 Kmi of use. If 200 Kmi is not long enough then use what is
commonly called instrument wire (finer strands, higher count) to replace the
conductors.
I pulled new conductors into the door without removing the dash, although
removing the dash would have made it much easier. I pulled the wires through the
wiring loom in two stages. First, from the under dash to the door void and
then to the switches. The hardest part is to get an initial pull cord through
the routing of the wiring loom. This is accomplished by pulling in a pull
cord tied to the first conductor which is withdrawn. Of course, as each
conductor is pulled through the loom a pull cord to be used for the next conductor goe
s along for the ride.
I pulled new conductors one at a time because I foolishly thought that I only
needed to replace one of them. One turned into two, two into three and so on
until I realized that I wound be stupid not to replace them all at that time.
It probably would be easier to establish a pull cord then remove all the
wires before pulling in the new ones, but, by no means, never go beyond removing
the first conductor until you have a strong pull cord in place. Also, when
you have completed all the wire pulling, leave a pull cord in the bundle in case
you have to revisit the wiring in the future.
Notes:
1/ There are dedicated lubricants made just for easing wires through
raceways. If you cannot beg some from a friendly electrician (you'll only need a
couple tablespoons of the stuff, at most) and you don't want a quart bottle of it
to become part of your estate, you can use a liquid detergent; Murphy's oil
soap works well.
2/ Nylon small stuff (twine) works well for the pull cord. For years I have
been using twisted polypropylene (I think) bailing twine for pulling cords.
Whatever you use make sure it is strong and knots well.
3/ The ends of the conductors you're pulling in have to be stripped and a
secure loop formed in them. Streamline the end with some tape.
4/ Always make certain that you are pulling in a pull cord with the
conductors.
Other than all the above, it is just tedium.
George
