Instructions needed for rewiring the entire vehicle?

BILLY WEBSTER

MEMBER
1972 VOLKSWAGEN BEETLE
4 CYL
2WD
MANUAL
200,000 MILES

I am rewiring the entire vehicle listed above that was gutted and started to be converted to a Baja and then left as is. I need to hopefully get a little insight on how to complete this. I bought a replacement wire harness for it and well to be honest I am color blind so it's a bit challenging. I have a few different diagrams I retrieved from the Chilton Library on the library website, but they are unorganized and hard to tell which apply to my specific type. It's a type 1 12 fuse block and everything was just cut and removed from the original wiring. Any suggestions/references?

1 Reply

KEN L

MASTER CERTIFIED MECHANIC
42,959 POSTS

Here is some information I found on doing the job and this guide should help as well.

https://www.2carpros.com/articles/how-to-check-wiring

Rewiring a classic vehicle like a 1972 Volkswagen Beetle, especially with the challenge of color blindness, can indeed be a complex task. However, with the right approach and resources, it's definitely manageable. Here's a guide to help you through the process:

Understanding the Wiring
Identify Your Beetle's Specific Model: There are variations even within the same year, so knowing the exact model of your Beetle is crucial. Since you've mentioned it's a Type 1 with a 12 fuse block, focus on diagrams that match this specification.

Use Detailed Wiring Diagrams: Since color-coded diagrams are not as helpful in your case, look for wiring diagrams that label each wire by its function or destination, not just by color.

Tips for Working with Color Blindness
Labeling: Use a label maker to create labels based on the wire's function or destination, which can be adhered to the wires.

Colored Tape or Tags: Have someone assist you in applying colored tape or tags to each wire according to its color, and then label each color with a written description of what that color represents.

Wire Tracing Tools: Use a continuity tester or multimeter to trace wires and confirm connections, rather than relying on color.

Magnifying Glass with Light: This can help in reading small text on diagrams or in making out subtle differences in wire textures or markings.

Step-by-Step Approach
Organize the Wiring Harness: Lay out the new wiring harness and familiarize yourself with its sections and connectors.

Begin with Core Systems: Start with essential systems like the ignition, lights, and charging system. This will help you break down the task into manageable parts.

Match Wires to Components: Using your labeled or tagged wires, match them to the corresponding components as per the wiring diagrams.

Work System by System: Progress through each system (ignition, lighting, etc.) one at a time, completing each before moving to the next.

Check Each Connection: After connecting each wire, use a multimeter to check for proper connection and continuity.

Secure and Protect Wiring: Use cable ties and protective loom or tape to secure the wiring and protect it from heat or abrasion.

Seeking Help
Professional Help: If you encounter difficulties, consider seeking help from a professional auto electrician, especially for complex circuits like the ignition or charging system.

Volkswagen Communities: Online forums and local clubs for Volkswagen enthusiasts can be valuable resources. Members often have specific experience with Beetles and can offer advice.

Reference Books: Besides Chilton, look for other manuals or books specifically for classic Beetles. "How to Keep Your Volkswagen Alive" by John Muir is a popular guide among Beetle enthusiasts.

Use a Helper: If possible, work with someone who can assist with identifying wire colors and verifying connections.

Document Your Work
Take Notes: Document every step you take, including where each wire is connected. This can be invaluable for future troubleshooting or modifications.

Photograph Your Progress: Take pictures as you go along. They can help you remember how everything fits together.

Rewiring a classic car is a big project, but with patience and attention to detail, it's certainly achievable. Good luck with your Baja Beetle project!