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Step 16Electrical System
We chose to make two isolated electric systems in this car, one for the function of the car and one to run the accessories. The car operation requires the ignition system, starting system and running lights, while the accessories are things like music, LED lighting and the air compressor. We did this so we never had to worry about running the car.
A 4000 watt inverter was incorporated into the accessory system to power the 110v music equipment.
Both systems batteries are charged via the engine generator with the use of a battery isolator. Because of our large power consumption, we also used a Honda generator for charging the accessory 12v battery bank, two 12v deep cycle batteries. A standard car battery was used for running the car.
All of these items are controlled from the dash switches and the disco box, and are securely mounted under the floor boards.
Early on in the project, we listed everything that we would want to run on these systems and purchased a new automotive wiring harness from Summit Racing. We then mapped out our component list onto the new harness and made our final wiring diagram. We made a mock up of the dash in paper and started to route wires to the different parts of the car. All this work was done outside the car on a large table. Once the dash was done, we added all the pre-made switch bundles to it. As the car was being built, things like the disco box, batteries, inverter, starter, and relays were mounted in the car waiting for the day when we would install and connect the dash and harness to them. While building the frame and shell we regularly met with Lauren (the wire goddess) to make sure we made room and paths for all the wiring.
The day finally came when the welding was done, paint was finished and we could now safely install the dash and harness. Thanks to all the planning, the dash slid right into the mounts, the wiring went down tubes on the right and left of the shell and everything connected right up! The only thing we couldn't get to work the first time was the horn! I was amazed!
Never again will I mess with running wire one at a time. We would have been inside the car for a week doing it that way.
Next time: replace the VW generator with an alternator. We are normally milling around the streets and that's just to slow for a generator to produce a good charge.
Still to ad: dash gauges, built in 12v charging system from 110v and more lights for the shell.
A 4000 watt inverter was incorporated into the accessory system to power the 110v music equipment.
Both systems batteries are charged via the engine generator with the use of a battery isolator. Because of our large power consumption, we also used a Honda generator for charging the accessory 12v battery bank, two 12v deep cycle batteries. A standard car battery was used for running the car.
All of these items are controlled from the dash switches and the disco box, and are securely mounted under the floor boards.
Early on in the project, we listed everything that we would want to run on these systems and purchased a new automotive wiring harness from Summit Racing. We then mapped out our component list onto the new harness and made our final wiring diagram. We made a mock up of the dash in paper and started to route wires to the different parts of the car. All this work was done outside the car on a large table. Once the dash was done, we added all the pre-made switch bundles to it. As the car was being built, things like the disco box, batteries, inverter, starter, and relays were mounted in the car waiting for the day when we would install and connect the dash and harness to them. While building the frame and shell we regularly met with Lauren (the wire goddess) to make sure we made room and paths for all the wiring.
The day finally came when the welding was done, paint was finished and we could now safely install the dash and harness. Thanks to all the planning, the dash slid right into the mounts, the wiring went down tubes on the right and left of the shell and everything connected right up! The only thing we couldn't get to work the first time was the horn! I was amazed!
Never again will I mess with running wire one at a time. We would have been inside the car for a week doing it that way.
Next time: replace the VW generator with an alternator. We are normally milling around the streets and that's just to slow for a generator to produce a good charge.
Still to ad: dash gauges, built in 12v charging system from 110v and more lights for the shell.
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