A couple of weeks ago I managed to fry the dashboard light circuit on the instrument cluster. Not that it wasn’t in sad shape already. I had patched various sections of the both the light circuit and the ground on the circuit sheet where the copper wiring was damaged. As a result, the need to replace the circuit sheet wasn’t a surprise, and I had been thinking about it for some time. I figured I could create a replacement wiring harness, using connectors from the original and sold 24 gauge wire instead of the plastic circuit sheet. First, though, I had to map out the circuit.
That took the longest, even with Bentley’s assistance. Eventually, using my digital camera, a lightbox, and Omnigraffle, I managed to create a circuit map which would serve as a guide for my new wiring harness
With that as my guide, I began using a DB25 connector and 24 AWG wire from Cat5e cable. The idea for using a DB25 connector came from a fellow Vanagon owner’s solution (link updated! Thanks Edward!). When complete, the new connector looked quite good. I was quite happy with my soldering.
Moving on, I used ring connectors for the fuel and temp gauges, and actually used the connectors to the tach, voltage regulator, clock, and oil pressure control unit by removing them from the original circuit sheet. This meant that I wouldn’t have to come up with adaptations in order to make the connections. On the original circuit sheet, there are a number of capacitors and resistors. These I decided to move to a circuit board, which I bought at Radio Shack. Finally, I soldered the lights (which I changed to LEDs) into the harness.
Overall, the result is quite good, and preliminary tests seem to indicate that I got the whole thing right. One thing I don’t like is that the dash lights are not easily serviceable. I may have to revise that to use some wire disconnects of some sort. For now, however, I can once again see my gauges at night.
ADDENDUM 03/08/2013
I’m clearly not alone in that I have received a number of requests to build something like this for other Vanagon owners. Unfortunately, while this is in concept a relatively simple wire-up, there are a number of complications which prevent me from being able to take on such projects at this time. First of all, I used parts from my old flexible circuit to manufacture the new wiring harness. I don’t have a stock of these parts, nor are many of them commercially available. Secondly, this isn’t a drop in solution, as I had to cut off the existing plug in the van to install the DB25. Unless you want to transport me directly to your house, you would have to do this yourself, and that requires a certain amount of wiring skills. There are other minor reasons why I can’t build these for others.So while it would give me great pleasure to help my fellow Vanagon owner out in this regard, I have to decline such offers.
I will happily answer any questions you have, should you decide to undertake this yourself. I am currently investigating the possibility of producing these commercially, but I cannot guarantee anything will come of that at this time. Thanks, and good luck.
-J
