Monday, May 2, 2022

How to Wire Diet

There's a lot of wire in a modern production car. The wire diet is a very useful (but also very time and labor intensive) part of a kit car build. Here's how I am doing mine.

There are a lot of features that were in the donor car that I won't be using in the kit, so I am just tripping wire out that is related to those feature. In this example, anti-lock brakes. Nope, no driver aids in the kit car. This is the connector that plugged into the ABS unit, and I don't wat it flopping around in the kit, so it's time to diet it.

Pick a wire attached to the plug. It doesn't matter too much which one you choose, because they are all coming out eventually. Cut the wire close to the plug.
And then chase it back through the rat's nest of wire. The harness went to all corners of the car, so it's possible that a single wire could be fifteen or twenty feet long, piled in with a few hundred others. 

Oddly, this reminded me a lot of chasing network cables through a crowded wiring closet. I guess my time in IT has some real-world applications after all.

When you get to the other end of the wire, cut it off there, too.

Then, you can bundle it all up and chuck it into the box of wire that you have already pulled out.
Repeat as necessary, until you've removed every wire from that plug. Chuck the plug into the box as well.

Then identify and diet the next unneeded plug.

You may note a couple of things in the background of this pic - first, my hands are filthy; and second, the orange bucket half-full of trash. Both of these result from having to remove a lot of electric tape and wire loom from the bundled harness. The adhesive on the tape, after years in the donor car, turns to goo that gets all over everything and is challenging to wash off.
 

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