A 100-amp Powermaster alternator...
A 100-amp Powermaster alternator was a no-brainer. When it comes to aftermarket alternators and starters, they're the only ones I've used for years. As you can see, we opted for a standard three-wire hookup and a natural finish versus a polished or chromed one-wire unit.
Relays
A relay is a component that allows low current to activate a much more powerful current without overloading a switch. They're normally found in circuits for headlights, air conditioning, power windows, electric fans, or other components that require a lot of amperage to start and/or run. Typically a relay only needs about 120 milliamps (0.120 amps) to be triggered and held closed, but can supply 30, 40, or more amps (depending upon its rating) to the load being fed. By making the relay the main switch in the headlight circuit and using the headlight switch as the trigger for the relay the amperage load is moved from the headlight switch to the relay, which is designed to do the job. It's basically cheap insurance that increases switch life and prevents circuit damage. You generally only want to run one component from a given relay, but you can use a single switch to activate multiple relays.
What You'll Need
Anyone who's going to rewire their car, or even perform routine electrical repairs, should invest in the proper tools. You don't need a toolbox full of sophisticated electrical equipment to install a typical aftermarket wiring harness or wire in a new stereo or other electrical accessories. Quality wire strippers, terminal crimpers, and a good test light are the few essentials.
It's always a good idea to have plenty of terminals and connectors-in a variety of sizes-on hand before starting a wiring job. Some kits supply an abundance, others only a few, but it's always easier to get them ahead of time instead of having to stop your work and run to the parts store. You'll also want to make sure you have a good supply of heat-shrink tubing, solder (if you so choose), and electrical tape. Oh, and you can never have enough zip ties. Trust me on that last one!
A 16-inch SPAL electric fan...
A 16-inch SPAL electric fan fit the bill for the King-T as we had mechanical fan fitment issues. We could have stuck with the mechanical fan we'd planned on running, but we would have had to omit the radiator hoses, and neither of us thought that was a good idea.
There's plenty of literature available on automotive electrical systems if you'd like to do more research. The websites and tech lines of the companies in our source box can provide a wealth of information. We'd also recommend investing in a repair manual-one with good wiring diagrams-for your particular vehicle. It's not only great for general reference, but can be vital if you're keeping any of your car's original electrical items (switches, ignition components, A/C, etc.).
All things considered, the aftermarket has taken much of the mystery out of re-wiring old cars. That's good, because doing your own wiring not only saves money and provides a sense of accomplishment, it also makes it easier to troubleshoot and make electrical repairs in the future. If you don't believe us, get out in the garage and give it a try. You may not be an electrical expert when you begin, but with the help of companies like Ron Francis, The Hoffman Group, and Watson's Street Works you may just feel like one by the time you're done.
Air Conditioning - 10 Gauge
Alternator - 10 Gauge
Ammeter - 10 Gauge
Cigarette Lighter - 14 Gauge
Clock - 18 Gauge
Coil Wire - 16 Gauge
Dome Lights - 16 Gauge
Driving Lights - 14 Gauge
Gauges - 14 Gauge
Generator (Charging) - 10 Gauge
Generator To Starter - 16 Gauge
Headlight Circuit - 14 Gauge
Headlight Switch To Fuse Block - 12 Gauge
Heater Leads - 16 Gauge
Heater Switch - 10 Gauge
Horn Button - 13 Gauge
Horn To Relay - 10 Gauge
Ignition Switch - 12 Gauge
Low-Amps Circuit - 18 Gauge
Parking Lights - 16 Gauge
Radio To Fuse Blocks - 14 Gauge
Single Bulbs - 18 Gauge
Starter To Relay - 16 Gauge
Stoplights - 16 Gauge
Tail Lights - 16 Gauge
Turn Signals - 16 Gauge
Cd To Fuse Block - 14 Gauge
Windshield Wiper & Washer - 14 Gauge
Though it's not a factor when using a high-quality aftermarket wiring system like our Bare Bonz system, choosing and using the correct wire gauge for any given circuit is a must for safety and reliability. This chart is a good guideline-keep it handy.
 As soon as Candy saw the Aurora...  As soon as Candy saw the Aurora gauges there was no reason to look at any others. She loves the look and I like the design and craftsmanship. |  Here's Candy's Bare Bonz fuse...  Here's Candy's Bare Bonz fuse box in its partially wired state. I like this design because it gives me the option of either running my wires from the power source or the component being wired. The labeled wires from Ron Francis makes it really easy, because not only are they color-coded and printed with circuit identification, but they're marked with a fuse box terminal number, as well-it's awfully hard to screw up when they make it this easy. |  The Aurora instruments had...  The Aurora instruments had really easy to follow instructions, too. It made it pretty simple to sit down at the workbench and whip up a cluster harness. Doing it in this manner sure as heck beats trying to make your connects lying on your back crammed under the dash. |
 A good set of wire strippers...  A good set of wire strippers and crimpers are a must have. Whether you're doing a complete wiring job or just making repairs, quality tools go a long way in end up with quality installations or repairs. |  Some folks swear by soldered...  Some folks swear by soldered terminals; I'm not so sure. Crimp-type items like these shown here work just fine as long as you pay attention and use 'em correctly (this is where those quality crimpers and strippers come into the picture). I figure if the OEMs (both domestic and import) use crimped connections, we can, too; besides, I've overheated soldered connections in the past ending up with failed circuits because the joints became brittle and broke. |  |
 Relays are musts in modern...  Relays are musts in modern automotive wiring. High-load circuits like headlamps and starters can and will overpower the ratings of most switches, degrading them over time. Relays basically cushion these switches from those high loads, letting them operate with much less stress and heat. |  Here's a good tip: When crimping...  Here's a good tip: When crimping connectors always make sure you do it from the back side of a terminal, not the side with the seam. Doing it in this manner makes for tighter clamping action and a more secure connection. |  Another thing I've learned...  Another thing I've learned over the years is to always make sure you've got an ample supply of connectors and wire ties on hand when tackling a wiring job. Wire ties are a must for keeping wiring organized and neat. |