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So, I noticed when I picked up my 86 sammi that lights were really dim and the heater blew extremely slow as well as the wipers ran extremely slow. the lights dimmed and brightened with RPM and first thought was alternator. I swapped it with a 110A model and things are glorious now however I still get dimming. I made sure belt was tight also When doing electrical work all wires seem brown and dingy.


So, my question i that I believe it is time for a complete rewire. Does anyone know of any kits that they make like they do for Scouts, Jeeps, etc? If not I will just buy a bunch of wire and go to town and make blueprints I was just curious though.
 

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Back in my VW days I remember seeing dune buggy rewiring kits but they are very universal, some with blinker & wiper functions etc. I think I would start by checking all grounds. I added a ground strap from engine to body and one from the back of the alternator to the body. I still have the wipers taking a moment to get up to speed but everything else works well. I had installed the old style int reg GM alt @94 amps and it was an improvement but found that voltage at idle was inadequate so when that one popped I went with the CS105 (88 Corvette puts the mounting ears in the right spot) style alternator which puts out stupid amounts of power even at idle. It's much improved now. Aside from the first couple wiper strokes being slightly slow its decent. On the volt meter I notice about a 1v drop from the charging system to the in cab systems but everything works as it should. Dash lights bright, perfect blinker operation. All my exterior lights are LED except HL. Good luck.
 

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Check and clean the ground wire points on the body before you rip into the wiring harness....
 

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+4 on the ground wire checking and cleaning. Get yourself a small wire brush and some electronic parts spray cleaner and clean most negative spots starting with the battery and that should do the job. Good luck.
 

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I actually have gone through the grounds with a fine tooth comb already. I added the body ground to the battery via a 10 gauge wire as well. I was thinking of going the route of a cs105 as well but had already spent a good amount on the kit I had which I still had to fabricate (Thanks Rocky Road!!) the brackets looked like they were cut by a two year old with a plasma cutter so I had to drill holes and enlarge a few. I had at the point had problems with my battery dying due to the tax on the electrical system and the new alternator did solve that. I have no hesitation in wipers or blower any more just headlight dimming that's it. I cleaned all grounds even added a little dielectric grease around them after assembly. I fine tooth combed all the grounds with a die grinder and dremel and some wire brush wheels til shiny haha
 

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That sucks to have to buy the kit and still have issues, I bought the lower bracket from Trail Tough I think, very nice piece. I then went to the auto parts house and bought the pigtail and installed it, modified the existing upper bracket to fit. I had to repeat when I moved to the CS105, actually just wired it in fresh taking field voltage from the battery and I wired in a CEL to (the 3 wire install) and delighted with it. I'm sorry your experience was less than excellent with Rocky Road but IMHO people gotta know before they throw their money at it. The main reason I upgraded to the CS is the older style GM alt did not put out adequate voltage at idle, everything went dim at 800rpm. Did they offer you a refund or exchange?

As far as headlights dimming mine did it to, even when all else was in order. I did the headlight harness upgrade outlined here. While I was at it I threw in a couple of those cheap-o composite headlights ($20 each from Summit) and tossed in a couple Osram Nightbreakers... I get an impressive amount of pure wicked light. Around here it's VERY dark at night, no street lamps and often its pitch black. I recommend this upgrade to anyone. The other Samurai that I just bought... dim headlamps to.

One thing I failed to realize right away that cost me some time while I was sorting through the HL harness is that it is a + gnd system.
 

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Checked the grounds at the fuse boxes ? the one under the hood is the important one...
 

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Presuming here that your "grounds" are good.

Have you actually meter sampled the voltage at key points, starting at the battery, alternator and fuse box? :huh:

IF all is well (13-15V running) at the battery power source, then it is a matter of tracing the + leads to their various end-use components, noting for any significant voltage drops along the path.
 
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