Posted by 5 of Johns 5 are 4x4 [166.70.201.2] on Friday, March 08, 2013 at 12:27:33 :
In Reply to: Wire melted in like 5 seconds! posted by Sterling From TX [99.98.76.231] on Friday, March 08, 2013 at 02:28:50 :
Sterling,
I am no expert, but I did design and build the entire wiring harness for my Jeep when I built it a few years ago, which allowed me to do things the way I wanted, like using relays to run my headlights, which eliminated the resistance in the dash switch, so I have very bright headlights using the standard halogen bulbs. (this is sort of related to my comment below)
Any time you get melting wires it means one thing, way too much load / current. This is usually caused by several things.
1 Dead short (as was mentioned) Just because it worked once before does not mean it did not get damaged or had a problem before. I have seen many things work once but a problem somewhere else was killing it and it was not obvious at first.
2 too much resistance, meaning the wire size is not up to the job you are asking it to do.
a heavy load item like a starter needs heavy wire to carry the current / amps needed to do the work. if the wire is too small then it acts like a resister, which builds heat and then melts. I would look at the diagram posted and your harness. Make sure you have the right wires and sizes for the job.
3 one of the comments asked about the different switches Dash vs. Foot.
(NOTE: this is where i need some help but i will try to explain what I know.)
the in-dash switch is designed for a smaller current that will switch a solenoid or relay that then runs the larger current for the starter itself I think this is designed for the Bendix style starters.
The foot starter switch was designed for direct switching of the starter (I Think)so it can handle the heavy load.
So you may need to look to see if you have all the right components for the type of circuit you are trying to create.
Anyone,
Please feel free to correct me as I said I am no expert but rather enough knowledge to be dangerous. : )
Follow Ups: