Electrical power distribution

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Hey All,
I did my own wiring and I’ve ended up with one big glob of supply wires (wire nut) and one big glob of ground wires in the headlight bucket. I’ve been looking for a better way to connect and distribute all these wires. Has anyone a suggestion? I’ve been looking for some slick piece of distribution hardware but have had no real luck.
Thanks,
Paul
Electrical power distribution
 
Roadrash said:
Hey All,
I did my own wiring and I’ve ended up with one big glob of supply wires (wire nut) and one big glob of ground wires in the headlight bucket. I’ve been looking for a better way to connect and distribute all these wires. Has anyone a suggestion? I’ve been looking for some slick piece of distribution hardware but have had no real luck.
Thanks,
Paul
Electrical power distribution

Interesting looking at your connections. Typical connections are red for common ground (+), while for live ignition, horn and brake light (-) and brown with green for running lights including instrument illumination. You have white hard wired to brown with green in the wing nut connector which should be switched in my thinking.
 
concours said:
The OEM type multiple bullet connectors work pretty well
I'm not making myself clear. That wire nut has one main power supply from the ignition. All the other wires twisted together with it go to the lights, horns and such. Same with the cluster of ground wires in the pic. I'm looking for a slick way to distribute/split the one supply wire to 10 or more destinations.
 
[Interesting looking at your connections. Typical connections are red for common ground (+), while for live ignition, horn and brake light (-) and brown with green for running lights including instrument illumination. You have white hard wired to brown with green in the wing nut connector which should be switched in my thinking.[/quote]

Yup, purist's will be annoyed, but I picked the wire colors based on local availability, then added number tags to keep track of everything. Factory colors will only be the lucas switch & light pigtails.
There is a logic to it. Red is + ground and black is - supply. destinations have their own specific color and or number. It' must be my background in construction instead of electronics :wink:
 
I haven't started the electrical on my bike yet but my strategy was to have a central fuse block and terminal strip to distribute to the individual circuits. I think that you need to have some terminations in the headlight in order to minimize wires at the steering head, but some of the distribution from the ignition could be eliminated. I also plan to put relays in the light circuit. There are some great wiring threads on the web for Norton's, do a search. There also are some very good "cleaned" up wiring diagrams out there too.
 
Do a search for Fuse Block and you wil find some good example of upgraded wiring. I am currenly rewiring my MK III, will post pictires soon. Using an Eastern Beaver PC-8 panel and 2 relays. 2 unswitched and 6 switched circuits.

Chuck
Saber 13
 
Marine supply stores (like West Marine, etc) carry high quality electrical parts and might have what you need.
 
http://www.digikey.com/product-detail/e ... ND/2051177

The above link shows a distribution block. I am not specifically recommending this one in particular, just want to let you know the type of stuff available. This one has 2 poles in with 8 out on each pole. 15 amp capacity is more than enough for any circuit on a MC, the voltage rating for this one is overkill. Screw connectors are reasonably vibration tolerant, but do not solder the wire ends, just mash the wire with the screws.

There are spring loaded Quick Connects (push in ) available for 2,3,4 or more into 1. These eliminate the wire nut junctions or splices and are cleaner. The best connectors from a vibration standpoint are crimp-to-wire bullet type with mating female J-block or individual mate (basically the type of connector you found on your Norton in the first place).

The DigiKey site is a good place to browse for termination and wire distribution products...they have good diversity and selection, and you do not need a commercial account to purchase.
 
texasSlick said:
http://www.digikey.com/product-detail/en/2315256/277-2005-ND/2051177

The above link shows a distribution block. I am not specifically recommending this one in particular, just want to let you know the type of stuff available. This one has 2 poles in with 8 out on each pole. 15 amp capacity is more than enough for any circuit on a MC, the voltage rating for this one is overkill. Screw connectors are reasonably vibration tolerant, but do not solder the wire ends, just mash the wire with the screws.

There are spring loaded Quick Connects (push in ) available for 2,3,4 or more into 1. These eliminate the wire nut junctions or splices and are cleaner. The best connectors from a vibration standpoint are crimp-to-wire bullet type with mating female J-block or individual mate (basically the type of connector you found on your Norton in the first place).

The DigiKey site is a good place to browse for termination and wire distribution products...they have good diversity and selection, and you do not need a commercial account to purchase.

Thanks Tex. That's a good lead.
 
Routing is the first thing to look at. I don't know where the horn is on your bike, my 850 Commando had it in the stock location down by the gearbox. In that case it would not make sense for me to run a hot to it all the way from the headlight when the battery is much closer to it.

Wire nuts do a good job in wiring buildings but I would wonder about using them for vibrating machinery, although I have never seen them come apart. I am a real electrician by the way, union trained and licensed etc..

I just made my own harness for the Norton I am currently riding. I tried to make it as simple as possible with as few wires as possible. The more simple any system is the less points has that can fail.

Make every wire as short as possible and still have it loose enough so it will not fatigue, no banjo strings. You must use all stranded wire, THHN is high temp and oil and gas resistant and is very easy to find.

I had two major points on my bike that I could attach power and ground wires too. I had one power and one ground connection right by the battery, and one in the headlight. Those two areas of a British bike are convenient to anything that needs electricity.

Types of connectors that are used to join wires where vibration and heat extremes are met are often a type of split bolt called a "bug" or Stake-on style crimp on loop terminals held together by small nuts, bolts and lock washers. I had two split bolt bugs right next to my battery, one positive and one ground. Each one of them accepted a wire right from each battery terminal making them positive and negative.
Also right next to the battery I had a loop crimp connector bolted to the frame as a chassis ground with a jumper going from it directly to the bolt that holds the Lucas rectifier to the chassis. Everything that needed power at the rear of the chassis has a wire going to the negative split bolt and everything needing a ground has a wire going to the positive split bolt.

One pair of positive and negative wires runs from the split bolts up to the headlight to power everything at the front of the bike. Put a few split bolts in the headlight to join those two with whatever is up there, it does not get any more simple. When you are done you first wrap the split bolts in thick rubber tape, and THEN in standard high quality electrical tape. Before I made all the connections I put shrink tubing over all the wires and hit it with a propane torch. I did not rely on the chassis as a ground. I ran a ground wire everywhere in addition to having the chassis grounded, that way you are not going to lose your ground if a chassis bolt or part comes loose. Use red for all positive wires and black for all negative wires. For control wires such as the turn signals you can get creative with the coloring.

Any good automotive parts store will sell bullet style crimp connectors that are male and female which you can use instead of Lucas bullet connectors. Marine and heavy truck specialists may have better selections.

If you like terminal blocks then go for it, but they are much larger than a small split bolt that will take half a dozen wires, plus they have to be mounted to something where the light split bolt connector can just float where it has to. An electrical supply shop can set you up with the right size copper split bolt or "bug" for the size and number of wires you need. I am guessing the price of it will be about $1 give or take. Also tell them you want some good quality Scotch rubber tape to wrap them with and if you can find it get a roll of Scotch 88 grade electrical tape, it is their highest grade with the longest life and temperature range.

That is my industrial style, stone simple and reliable wiring harness.

Don't forget the fuse on the battery negative. I think most British bikes had about a 35 amp fuse there, which is odd because I don't think anything on the bikes draw that much current unless you are talking electric start. Also in an enclosed raceway #14 wire is usually fused at 15 amps and #12 wire at 20, so running 35 amps through either of them could burn off the insulation. I would try a 20 amp fuse on a non electric start bike and go up only if you find a problem with it, it will offer more protection than a larger fuse.
 
Roadrash said:
concours said:
The OEM type multiple bullet connectors work pretty well
I'm not making myself clear. That wire nut has one main power supply from the ignition. All the other wires twisted together with it go to the lights, horns and such. Same with the cluster of ground wires in the pic. I'm looking for a slick way to distribute/split the one supply wire to 10 or more destinations.

I understood you perfectly, but was not at a full keyboard to make a proper response. This, with a couple jumpers daisy chained does the job, easily remove wires singly for troubleshooting, use standard parts, etc.
http://www.britishwiring.com/C-336-p/c336.htm
 
+1 on Beng's comments, particularly only stranded wire and shrink tubing. THHN is all Beng claims, but I prefer MTW wire. It is more compliant, holding bends and shape better than THHN, and is more like the automotive wire we are all accustomed to. Or, use the automotive grade wire that you can get from your friendly parts house.

There is all good info on this thread.....but please....clean up that rat's nest in your headlight bucket!

Slick
 
texasSlick said:
+1 on Beng's comments, particularly only stranded wire and shrink tubing. THHN is all Beng claims, but I prefer MTW wire. It is more compliant, holding bends and shape better than THHN, and is more like the automotive wire we are all accustomed to. Or, use the automotive grade wire that you can get from your friendly parts house.

There is all good info on this thread.....but please....clean up that rat's nest in your headlight bucket!

Slick
A rats nest that starts on the first kick, runs like a top. the rest is details :wink:
 
Roadrash said:
texasSlick said:
+1 on Beng's comments, particularly only stranded wire and shrink tubing. THHN is all Beng claims, but I prefer MTW wire. It is more compliant, holding bends and shape better than THHN, and is more like the automotive wire we are all accustomed to. Or, use the automotive grade wire that you can get from your friendly parts house.

There is all good info on this thread.....but please....clean up that rat's nest in your headlight bucket!

Slick
A rats nest that starts on the first kick, runs like a top. the rest is details :wink:

All in good fun! But pretty counts for something.....but hey!....I'm an engineer...if it works ...it's good!

I would not have made that snide comment if I did not think you sincerely wanted to improve your wiring.....that is why you started this thread....right? A clean wiring job means less headaches when troubleshooting a problem next year. In that regard, be sure to make yourself a wiring schematic...now...before you forget what you done!!

Slick
 
All true Slick.
But you know what I'd like to see now, is a pic behind someone's headlight that's proud of their rat's nest... Show em to me!
 
Roadrash said:
All true Slick.
But you know what I'd like to see now, is a pic behind someone's headlight that's proud of their rat's nest... Show em to me!
Is this what you meant? It looks pretty disorganized, but it's kinda like one's desk. Looks like a rat's nest to anybody else but you.

Electrical power distribution

Electrical power distribution



I like the idea of cutting down on the wires and connectors on the frame. If I was going to do it again I'd get one of the better fuse blocks and use gasketed connectors. There's some heat shrink tubing at DigiKey that has a rubber-like pliability along with a heat activated adhesive. Much better than the stuff at the electronics store. Modern connections with gaskets are nice too. All this stuff is pricy and you don't even get to show it off. Also, i'd get correct color coded wires for the sake of posterity. If you never ride in the rain most of that stuff is probably not necessary.(After getting tailgated a few days ago that was the closest I've ever seen, I'd like to fix up a solenoid activated pressurized spray of artificial skunk essence.)

http://www.fuzeblocks.com/
http://www.easternbeaver.com/Main/main.html


Electrical power distribution

Electrical power distribution
 
beng said:
Wire nuts do a good job in wiring buildings but I would wonder about using them for vibrating machinery, although I have never seen them come apart. I am a real electrician by the way, union trained and licensed etc...

Wire nuts are indoor rated...they corrode in outdoor environments. Most outdoor electrial components if they are to be subjected to moisture are sealed and or imbedded in dielectric grease or silicone sealant. Vibration is also an issue. Not a good choice for a motorcycle.
 
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