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| 1956 DJ Wiring Adventure | |
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| Tweet Topic Started: Dec 4 2014, 05:04 PM (1,647 Views) | |
| PapaC | Dec 9 2014, 12:01 PM Post #16 |
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Papac
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I'm a ways away from actually picking the lock and getting into the tumblers but I'm sure glad to hear it can be done!! By now I'v got the dash cluster the key switch, and part of the light switch and dimmer switch wires made. For me, de-coding the little bitty image of the harness diagram, understanding the subtle differences in the way a couple of the wires run compared to the original I'v got, figuring out and understanding for sure that these differences accomplish the same thing in the long run, and documenting the lengths and what I think are the correct colors is every bit as hard as doing the actual work itself, maybe harder. That being said, last night I spent several, several hours salvaging these ends. ![]() They now need final cleaning and re-tinning before using. While doing them I destroyed three of them (not shown) and two shown have broken ears. Taking the temper out of and softening the old brass is a delicate procedure and its a good thing I have extras so that i can use the best of them. I'm especially proud of the bakelite? three way connectors. Those would have been a bugger to come up with. I had bought some but they're not near the quality of these old ones. Old ford one way and two way connectors are easier to find for sure and they will work. I'm not even going to try to reuse the old bullet connectors. The one shown on the left is an old 'wiry joe' and the one on the right is original. The wiry joe's are hollow through the middle, pre-tinned inside and appear to be every bit as good quality as the used ones. I'v got a box full of them so I'm almost to the point that I can rock right on through this thing. Unknown wire lengths such as the headlight, tail light, gas tank sender, and sparton harness, along with a couple of the engine wires I'll leave plenty enough extra length to cut and put the ends on at the last minute. Also I don't have the wire loams or the wiring tape yet so I have to be careful about putting some ends on until I obtain them and slide the correct wires through them. |
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Charles Tate....North Mississippi 1956 WILLYS DJ3A Convertible Doing ground up nuts and bolt restoration by almost entirely reconditioning original used or a few NOS DJ3A parts. 1962 WILLYS DJ3A Convertible. (For research and parts only) | |
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| oldtime | Dec 9 2014, 12:07 PM Post #17 |
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MODERATOR
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I know the pain Charles. Been there and done that because I'm just that cheap ! And will likely do it again. Keep up the effort, it will pay back in due time. |
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Currently building my final F-134 powered 3B . Rock Crawler using factory parts from the Willys Motors era (1953-1963) http://s4.zetaboards.com/CJ3B_Bulletin_Board/topic/30228766/1/#new | |
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| PapaC | Dec 10 2014, 01:49 PM Post #18 |
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Papac
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A bit under the weather at the moment so having to take a short break. I expect that won't last long. I believe these connectors were made by Auto-Lite At least there's some nos ones an ebay that appear the same. Hugely inflated prices. Asking price including shipping. 33.00 for TEN! Also a make offer option but....I'm too cheap for that too!! No modern connectors I'v seen actually compare. Now look at this ![]() You have to have x-Ray vision to understand that you're looking through the cluster on this diagram. You have to kind of mirror image it if you're looking at the cluster from the back. The wires are not identified as to which exact posts they hook to on the key switch, light switch, etc. The recent search function on this page is awesome. Searching for wiring now easily brings up Ken's notes (posts) that includes the correct points to hook the wires to on each component and many many of the colors. Cost savings wasn't the only thought behind this. Originality was in my thoughts. Wallacks and other such venders can't be considered so because the harness's have been redesigned for their cost savings. Pretty sure Rode Island Wiring would be the closest from what I'v heard but prices WAYYY beyond my reach. Mine can't be conisidered original...ever...but at least I can go the extra mile in duplicating what I know or can find out to be original including the integrity, original ends and the original lengths, wiring routes and everything else that I can including heavier gauge wires and better ends than most aftermarket. Should it matter, probably not but to me it does. I convince myself that's how I do my small part in saving a piece of history and made an adventure out of it. My hugest inspiration was first the fact that it's been done before by someone who is cheap.... :).....but more importantly took the time and care to make notes and post here that matter. |
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Charles Tate....North Mississippi 1956 WILLYS DJ3A Convertible Doing ground up nuts and bolt restoration by almost entirely reconditioning original used or a few NOS DJ3A parts. 1962 WILLYS DJ3A Convertible. (For research and parts only) | |
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| PapaC | Dec 18 2014, 06:47 AM Post #19 |
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Papac
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I'm still working on it Bill but not there Yet. EDIT: image being revised |
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Charles Tate....North Mississippi 1956 WILLYS DJ3A Convertible Doing ground up nuts and bolt restoration by almost entirely reconditioning original used or a few NOS DJ3A parts. 1962 WILLYS DJ3A Convertible. (For research and parts only) | |
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| PapaC | Dec 20 2014, 10:06 AM Post #20 |
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Papac
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6 VOLT 1956 DJ3A DISPATCHER WIRING DIAGRAM WITH KING SEELEY SPEEDOMETER ![]() 6 VOLT 1956 DJ3A WIRING SCHEMATIC WITH KING SEELEY SPEEDOMETER EDITED
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Charles Tate....North Mississippi 1956 WILLYS DJ3A Convertible Doing ground up nuts and bolt restoration by almost entirely reconditioning original used or a few NOS DJ3A parts. 1962 WILLYS DJ3A Convertible. (For research and parts only) | |
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| F Bill | Dec 22 2014, 11:40 AM Post #21 |
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Jeep discovery and aquisition specialist
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holy Toledo, I think we have a new wiring expert among us!! THAT is a beautiful rendition.....I'd be proud to hang that on my living room wall! (insert crowd clapping icon here...(and not the golf clap either..) ) It is in the same class as the Autos of Yesteryear feature "comic" panel that used to run in the papers of the 70's......or the exploded diagrams in the How to Keep your Volkswagen alive by John Muir... I am blown away. |
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59 convertible 15933 needs drivetrain 60 convertible 17052 has a V6 and 4WD 60 Surrey 17509 went thru Katrina and looks it. 60 Surrey 17918 started it all...Toyota axle, BW Wrecked Surrey Tub with fenders and grille 56 tub, from 11826 And a couple parts DJ's with no ID left. All my jeeps are projects....only runner is my DJ with doors.. | |
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| PapaC | Dec 23 2014, 02:03 AM Post #22 |
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Papac
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Well heck, Bill it was your idea. I was just trying to get where I could read it. There's still a few discrepancies to sort out between the original diagram and the warning harness I have. For now the schematic is mostly based on the original willys drawing. My original harness has a few differences which I can now easily sort out. Wire colors were based on various cj notes around the web including CJ3B's, CJ2A's, CJ3A's and published colors of economy aftermarket wiring harnesses. Now going back and comparing to my old harness I'm going to correct a couple of the colors and do some more investigating. I don't think its a coincidence that the bigger the wire the more tracer stripes. Somewhere I found a Willys memo that mentioned there may sometimes be descripences, I believe due to what might be available concerning wiring but sadly I didn't bookmark it and can't find it again. TO RE-Tin Old BRASS CONNECTORS After cleaning heat and apply acid core solder. Rosen core doesn't like to stick to brass. Don't worry about build up or getting too much, just make sure it's all covered and lay aside. Once they're all done grip a edge somewhere on the fitting and reheat with a small torch. When the solder starts melting gently bump the pliers against something steel. Make sure the tiny little splash is going away from you, and the excess solder will fly off. You can repeat if needed. While hot drop in a cup of vinegar. This will remove any excess acid that might prove harmful later. Then when you pinch in your pre-tinned wire (always use Rosen core on electrical wires, when you heat to solder it'll almost stick itself, maybe just a 'touch' of Rosen core to make a complete bond. |
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Charles Tate....North Mississippi 1956 WILLYS DJ3A Convertible Doing ground up nuts and bolt restoration by almost entirely reconditioning original used or a few NOS DJ3A parts. 1962 WILLYS DJ3A Convertible. (For research and parts only) | |
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| PapaC | Dec 26 2014, 09:39 AM Post #23 |
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Papac
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Made a couple of changes in the schematic and edited the picture. One wire going to the brake light switch was base color green, couple of things like that. Also changed possible catastrophic mistake on the starter wiring. Somebody take a look at it and see if that doesn't look more right. In so doing I discovered my own starter had a wrong 4 post solenoid and I now believe it calls for a 3 post solenoid. I'v got one laying around here so I'll test it before putting it on. The under dash harness is now almost complete except for labeling, covering the connectors with shrink wrap and stripeing the wires with little dots. ![]() As soon as I get bullet ends on this side of these wires ![]() I can take the whole shebang out to the jeep and get the rest of the correct measurements with wire in place. Then I'm taking the whole wiring harness back apart for labeling and finishing and getting ready for wiring tape and sheathing which I still don't have. I might just put the tracers on the end sections of each wire to save time, I haven't decided yet. Even though I don't have any tattoos I figured out I sure could use a tattoo machine with a dull needle to apply those dots!!! Strip around en with some tape and dot away. Unfortunately I don't though so I'v still got my thinking cap on. Did you know Thomas Edison invented the modern tattoo machine due to another failed invention of his that went bust!!! It was supposed to be a elaborate copy machine but soon the Xerox machine was invented and made them obsolete. A guy who did tattoos bought one out of a pawn shop, modified it, and boom, there you go. Modern tattoo machines still work the exact same way, just with more modern designs. |
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Charles Tate....North Mississippi 1956 WILLYS DJ3A Convertible Doing ground up nuts and bolt restoration by almost entirely reconditioning original used or a few NOS DJ3A parts. 1962 WILLYS DJ3A Convertible. (For research and parts only) | |
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| PapaC | Dec 27 2014, 02:43 AM Post #24 |
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Papac
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Some progress ![]() Bullet ends installed, crimped, and soldered. _____________________________________ ![]() ![]() Note: last two photos believed to be original cj3a wires. Best guess is one is battery terminal of voltage regulater to starter solenoid. Second is 'possible' coil to distributer wire??? Unusual to me is the spiral wrap, some type of plastic?, encircling this wire. Whatever it is it is NOT tape. The first wire appears black with three white dotted tracers. The possible coil to distributer wire color is unknown at this time. (Dirty) Ps. Soon I should hold the world record for taking the most time to build a wiring harness. I'm not sure if that's a good thing or bad thing!!!
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Charles Tate....North Mississippi 1956 WILLYS DJ3A Convertible Doing ground up nuts and bolt restoration by almost entirely reconditioning original used or a few NOS DJ3A parts. 1962 WILLYS DJ3A Convertible. (For research and parts only) | |
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| PapaC | Jan 16 2015, 11:04 PM Post #25 |
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Papac
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Almost getting ready to get back to business and finish wiring the 56. Many of the correct lengths have already been added to the schematic. Fully expecting my 'new' DJ convertible to help with that even though 'it' has the more modern plastic wires. In the meantime I managed to snag onto this....complete with keys and guaranteed to work.... for less than a song. Not NOS but I couldn't pass it up. (20.00 including shipping from one of my favorite ebay sellers). From the pics looks like it'll polish up real nice. ![]() Sure would save some difficulties down the road if these keys would fit the other ignition switch too. Crossing Fingers!!! |
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Charles Tate....North Mississippi 1956 WILLYS DJ3A Convertible Doing ground up nuts and bolt restoration by almost entirely reconditioning original used or a few NOS DJ3A parts. 1962 WILLYS DJ3A Convertible. (For research and parts only) | |
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| PapaC | Feb 11 2015, 01:19 PM Post #26 |
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Papac
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A few weeks ago I installed the harness, made sure everything was going where it was supposed to go, and then took it back off and packed it up for later final installing. In the meantime I got my hands on a big box full of this...assorted sizes....for when I get ready to reinstall the harness. ![]() Just goes to prove one mans leftovers is another mans treasure!!! |
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Charles Tate....North Mississippi 1956 WILLYS DJ3A Convertible Doing ground up nuts and bolt restoration by almost entirely reconditioning original used or a few NOS DJ3A parts. 1962 WILLYS DJ3A Convertible. (For research and parts only) | |
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3:53 AM Jul 11