Custom Loom ELECTRICAL ADVICE

[Royalratch]

Cheers Rick - yeh I just used what I thought was generic Automotive colours.

So nice thing simple cables for inputs and just ensure thick enough cable for the relevant loads.

Dumb question - what's to stop you just using fat 30amp cable on everything and be done with it? Just excess weight?

[j.wilson]

Of course thick cables are an alternative, however there are some issues-

first the range of colours is not as great
bend rads are smaller- helps when fitting everything into the headlight for example.
the cables are stiffer so the fatigue and vibration can be more of an issue
getting the loom thru tight spaces can be more difficult
Fitting the wires into the connectors is difficult- depending on what type of connector you go for.
The loom under the steering head can be more of a problem to get the flex needed without making the whole loom move.

Many of these issues disappear with your set up- so it is an alternative for you- although I'm not sure the real benefit.

Sounds like you are going to run the headlight on all the time- so you need good cables on that circuit, after that, good cable to your relay box, and I like the idea of welding cable to and from the starter and motor earth.- oh and good cable to your ig box and coils.
Don’t get too hung up on it all, you don’t have many long high current runs- only the headlight as far as I can see- so that circuit is the only one where power drop is an issue (all the way back to the relay box).
As for flasher and the horns- they use power just not for very long- so I would not get too hung up on them.

I used thin wall cable from Vehicle Wiring Products and invested in some decent wire strippers and crimpers.

Finally, the big issue for me was the pvc sleeving I put all the loom in. I like the black shiny stuff, and I used as small a dia that I could get away with.

As for the junctions in the loom I would make a hole in the pvc sleeving and thread the new wire or wires into it, then I put these in a smaller dia pvc tube. Finally I used adhesive lined heatshrink to go over the whole joint to seal and stress relieve it.
It’s a neat solution and easy to keep clean.

You inspire me to go for really neat wiring- perhaps my next project should have as simple wirings as possible and much of the loom hidden as possible.