[email protected] – 6/22/14 – page 1 of 7 bugeye wiring the original wiring on an unmodified car was...
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[email protected] – 6/22/14 – Page 1 of 7
Bugeye Wiring
The original wiring on an unmodified car was marginal with a generator and only 2 fuses. The lights are problematic due to the ground connections that are strung together with bullet connectors. Then add an electric fuel pump and higher power lights and it gets more fun.
The main upgrades I have planned are relays for the high current devices and convert to alternator charging. I broke the system into 5 main circuits that are each fused:
1. Headlights2. Horn3. Lighting
• Brake lights• Parking Lights• Gauge Lights
4. Key Switch• Ignition• Fuel pump• Flashers• Wipers• Heater• Tach• Fuel Gauge
5. Power Port
The following page shows a state table that defines what should be powered for each combination of the key switch and light switch. Each state is controlled by relays.
[email protected] – 6/22/14 – Page 2 of 7
STATE Definition
OFF HornAUX Brake Lights
Key-on(I)
IgnitionFuel pumpFlashersWipersHeaterTachFuel Gauge
S Parking LightsDash Lights
H S + Headlights
Switch States Defined
•S
•I
•B
•H
Ignition Switch
B = BatteryS = Parking LightsH = HeadlightsI = Ignition
BATT +
Functional Wiring
HORN
BRAKE LIGHTS
12V AUX
IGNITIONFUEL PUMPFLASHERSWIPERSHEATERTACHFUEL GAUGE
PARKING LIGHTSGAUGE LIGHTS
HEADLIGHTS (LOW)
I
S
H HEADLIGHTS (HIGH)
Even thought there is only one switch, The key independently controls the ignition (I) and the lights are either parking (S) or headlights (H)
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HORN
STOP LAMP SWITCH
IGN COIL DISTRIBUTOR
IGN/LT SWITCH
B
HS I
WIPERMOTOR
WIPERSWITCH
HORN BUTTON
FUEL PUMP
STARTERSTARTER SWITCH
HIGH
LOW
HORN
I
H
BRAKE
S
+
-
ALTERNATOR
1B 2
DIP SWITCH
FLASHERSWITCH
FLASHERRELAY
ACC
FUEL
BT L
SPEEDO
IGNL
TACH
HI
TB L
OIL/WATER
L
TANK
FLASHERLAMP
DASHLAMP
50Ω
Wiring DiagramFLASHER/SIDE LAMP HEADLAMP FLASHER/SIDE LAMPHEADLAMP
FLASHER LAMP STOP & TAIL LAMP STOP & TAIL LAMP FLASHER LAMPLICENSE PLATE LAMP
[email protected] – 6/22/14 – Page 4 of 7
+
-
ALTERNATOR
1B 2 IGNITIONLIGHT
IGNITION
150Ω
Circuit Descriptions
Charging
With an alternator conversion, the charging circuit becomes simple. I chose a standard GM (10-SI,12-SI) 3 wire internally regulated alternator. These are widely available since there were used on most GM cars and light trucks in the 70’s and 80’s.
Terminal-B is the battery terminal and connects directly to the battery for charging.
Terminal-1 is the field excite/warning light indicator input. This one needs 12V to initiate charging. A light bulb can be put in series to serve as a warning light. The warning light will illuminate if the ignition is turned on and the alternator is not supplying enough voltage. The resistor is a backup to maintain charging if the bulb burns out.
Terminal-2 is the remote sense input. It should be run back to the batter or fuse box. This will regulate the voltage at the battery rather than the voltage at the alternator. More details on this here
IGN/LT SWITCH
B
HS I
HIGH
LOW
H
DIP SWITCH
Headlights
Headlights draw up to 65w each which equals about 11 amps for the pair. Relays are a better option than running that current though the light switch and the dip switch.
I chose to have the “H” relay drive the relays for the LOW and HIGH beams. When the lights are turned on current passes through the NC contacts of “H” and energizes the low beam relay. If high beams are requested by the dip switch, “H” moves to the NO position turning off the low beams and turning on the high beams.
[email protected] – 6/22/14 – Page 5 of 7
Physical WiringTo keep the wiring organized in my head and on the car, I broke it up into 4 sections that all meet at the relay or interconnect panel.
• Dash – switches, gauges, controls, …• Engine – alternator, coil, wipers, horn, …• Bonnet – all frontal lighting• Rear – rear lighting, fuel pump, fuel gauge
There’s a terminal strip for each section on the relay panel. The relay panel will be located on the right fender near the original regulator and heater fan, or in the passenger foot well under the heater fan location.
[email protected] – 6/22/14 – Page 6 of 7
IGN/LT SWITCH
B
H
S
I
WIPERSWITCH
HORN BUTTON
DIPSWITCH
FLASHERSWITCH
FUEL
BT L
SPEEDO
IGNL
TACH
HI
T
B
L
OIL/WATER
L
FLASHERLAMP
DASH LAMPSWITCH
150Ω
Dash Wiring
1
1
2
2
3
3
4
4
5
5
6
6
7
7
8
8
9
9
10
10
11
11
13
13
BATTERY
(S) PARKING LIGHTS
(H) HEADLIGHTS
(I) IGNITION
GROUND
DIP SWITCH
HORN BUTTON
ALT LIGHT
FUEL GAUGE
WIPER
LEFT FLASHER
RIGHT FLASHER
14
14
FLAHSER LAMP
15
15
TACH
12
12
CENTER FLASHER
(H) H.LIGHTS(S) P.LIGHTS(I) IGNITION
DIP SW/HI BEAMHORN BUTTONHORNALT LIGHTFUEL GAUGEWIPERTACHFL LAMPLEFT FLCENTER FLRIGHT FLAUXBRAKE LIGHTS
LOW BEAM
16
16
AUX
[email protected] – 6/22/14 – Page 7 of 7
1
2
3
4
5
6
M
Relay Panel
11
22
33
44
55
66
77
88
99
1010
1111
1313
BATTERY
(S)
(H)
(I)
GROUND
DIP
HORN BTN
ALT LIGHT
FUEL GAUGEWIPER
LEFT FL
RIGHT FL
1414
FL. LAMP
1515
1616
TACH
1212
CENTER FL
AUX
11
22
33
44
55
66
GROUND
HIGH BEAM
LOW BEAM
PARKING
RIGHT FL
LEFT FL
GROUND
PARKING
BRAKE
RIGHT FL
LEFT FL
FUEL PUMP
FUEL GAUGE
11
22
33
44
55
66
77
11
22
33
44
55
66
HORN
COIL
BRAKE SW
ALT LIGHT
TACH
WIPER
HIGH
LOW
H
BRAKE
HORN
S
I
FLASHERRELAY
BONNET
ENGINE
REAR
DASH
FUSE BLOCK