I haven't met too many folks who have enthusiastically dug into their rig's electrical wiring without some confusion. At first glance, a vehicle's electrical system and the installation of new gauges seem as if they would require a degree in engineering or at least weeks of studying wiring diagrams and schematics-but that isn't so.
The idea behind this scratch-built Scrambler is to construct a vehicle that I know like the back of my hand and that will hopefully last a lifetime. Sure, I may work my way through a few engines and transmissions, but when any component need replacing I'll know exactly what it takes to get the job done. All vehicles should be built this way.
I've rewired entire vehicles from scratch and installed gauges before, so I can tell you it can be a major pain. Chasing electrical problems is time-consuming and irritating, so I picked up a Painless Performance wiring harness for an '81-'86 Jeep CJ. I also rounded up some cool new Pro Comp Ultra-Lite gauges from Auto Meter. The Painless harness is bundled and complete, and the Auto Meter gauges are a breeze to install. It would take a book to show you every electrical hookup involved in this installation, so here are some highlights.
 1. Wiring this scratch-built...  1. Wiring this scratch-built CJ-8 was easy. The harness will be routed up and out of the way of any moving parts, yet still be accessible if it needs servicing. This Painless harness is an exact replacement for the '81-'86 CJ and has all color-coded wire leads to any component fitted to a factory vehicle. |  2. It's recommended that the...  2. It's recommended that the wiring harness is laid out next to the Jeep so the installer can become familiar with it. The harness is divided into three sections. The forward section is not engine-specific but has the leads to engine components such as the coil, distributor, alternator, starter, and headlights. The aft section of the harness connects the dash gauges, ignition switch, warning lights, and HVAC. The tail harness powers the taillights and also contains the lead to the fuel tank for the dash gauge. |  3. Even guys with little or...  3. Even guys with little or no automotive electrical experience should be able to figure out this wiring harness fairly quickly. Every wire is tagged, so there is little question about which wire goes where. These harnesses are also available for Jeeps, trucks, early and late-model Ford Broncos, Toyota Land Cruisers, International Scouts, and custom applications. |
 4. The fuse box would bolt...  4. The fuse box would bolt directly in as a replacement to a CJ fuse box. I had to drill out the firewall to mount this box a little lower than factory so I could easily reach the fuses. The engine compartment harness plugs directly into the opposite end of the fuse box on the other side of the firewall, making a tight, waterproof, dustproof seal. |  5. The harness should be mounted...  5. The harness should be mounted up and out of the way of all moving parts and away from high heat sources like the exhaust system. The tail harness should be routed as high as possible up along the top of the framerail. This section of the harness receives a lot of abuse on the trail, and branches and rocks have a tendency to rip off low-hanging components. |  6. This is the pattern I sent...  6. This is the pattern I sent Aqualu Industries (the same company that made my aluminum Scrambler tub) to have the dash cut out for the Jeep. My masterpiece wasn't that important, it only needed to show where I wanted the gauges placed. The important information Aqualu needed was the exact gauge hole dimensions. Aqualu input this data into CAD software, and I had a perfectly cut dash in just a few days. |
 7. The Auto Meter gauges are...  7. The Auto Meter gauges are simple to install. Once the gauge is placed in the dash hole, the mounting bracket slides over the rear of the gauge and is securely held in place with two thumb nuts and lock washers... |  ...These premium liquid-filled...  ...These premium liquid-filled gauges are bulletproof and designed for abuse. The liquid silicone compound provides extreme vibration damping and smooth pointer movement. |  8. Don't be cheap. Use the...  8. Don't be cheap. Use the best wire connectors. It's well worth spending a few dollars more on the Painless Extreme Condition wire connectors. These are heat-shrink connectors and make a permanent connection... |
 ...When organizing any wiring,...  ...When organizing any wiring, these stick-on wire tie holders work very well. However, it's important that the surface they are stuck to is thoroughly cleaned with a solvent or else they won't last very long. | | |