motors, burned-out bulbs and poor grounds will determine what parts
need specific attention in a partial restoration. Also, examining such
components before disassembly can help the restorer understand how
those parts go back together during reassembly.
Once all of the electrical components are made to work again,
Kopecky recommends tagging every wire to identify its place in the car
after the battery is disconnected, even when a new harness will be used.
Also, photograph any areas where the wire is grounded as well as its
path as it winds through the car. Make sure the photographs show the
complete context to guide you to the location later; if that’s not possible,
make a sign and place it within your photograph to pinpoint where the
photograph is being taken. If you’re not sure of a wire’s correct location,
now is the time to refer to your car’s shop manual, a reference no
restorer should be without.
“I recommend a [shop] manual,” Kopecky said. “It’s my bible. Some
guys read the manual front to back before they start [restoring a car].”
The shop manual not only includes the wiring (including its color,
gauge and path), but often also includes the correct sizes for the bulbs.
“A lot of times, the bulbs in the car might be the wrong size,” Kopecky
added.
Also note and photograph the grounds and the hardware used to
attach the wiring to the car. If the hardware appears to be original, it
will need to be restored and reinstalled. If the factory wiring path
appears to compromise the stability of the wiring with sharp corners and
bends, seek a nearby path that will avoid these areas that could crimp it
or slice it open.
With the battery unplugged, removal of the old wiring can commence.
Kopecky begins at the rear of the car and works toward the instrument
panel, stopping when he gets to this point. He exercises caution when
pulling the wiring through small crevices in the car to ensure the old
wire doesn’t break further and his tags are not torn off. For the wiring at
the front of the car, Kopecky works from forward-most point
(headlamps, turn signals, etc.) towards the instrument panel.
With the wiring removed from the car, Kopecky lays it out on a clean
area of his floor and notes any breaks, cuts and any other trouble areas if
it’s being reinstalled. With the availability of wiring harnesses from a
variety of sources today, Kopecky does not recommend reusing an old
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