UPDATE on my electrical saga (finally I think we got it licked)...

[Jet Jockey]

Well the car is running and most of the electrical is done. I will continue to work on it but other things need to be done. We might still clean up the electrics but that would be next winter only. For now I'll call it 98% done and live with it for the summer months.

It is unbelievable how much electronics there is in this car. We had to change the set up to my temporary dash because even the darn emergency flashers are electronic and would not work! I had to buy a more normal VW switch with a built in relay to get my for way flashers to work.

Additionally we found out that everything in or on the steering wheel is also electronic. My plan was to keep the windshield wipers and the washer unit operating through the OEM stalk, same thing with the regular L+R flashers including the high beams but no they have built in electronics and circuit boards in them too and need an electronic power box that we decided to remove. Same thing with the steering wheel angle sensor, that's now out and that also affected the ABS system which I can no longer use. We tried to bypass the steering wheel sensor to get the ABS to work but I decided we had spent enough time and money trying to do so when in a couple of weeks I'm going to completely remove the ABS system in the remake of the brake system of the car when we install the rear BBK.

So here is what is left of the electrical system (fuse box/fuses and relays) on my car. We moved things around to make it more compact.


Here the driver’s side where most of the OEM electrical system is stationed. Now all that’s left is a few relays and fuses with some power for the horn, the new cluster and IIRC the fuel pump. You can also see at bottom left some plugs that are not used at this time. These all go to the front into the engine bay via the left fender. Some go to the ABS system.




Different angle of the driver’s side… Pretty big clean up!




Now a lot of relays and fuses were move to the passenger’s side. Most of these are for the ECU. This side still needs to be cleaned up but I have to wait and see how the OEM dash and perhaps a new centre console will work together to cut and finally hide the wires.




Here’s how it looks from the driver’s door.




Here’s the latest (temporary) dash with it switches.




Here’s what we took out. I have not weighed it yet. Box #1 is about 12 inches high by about 20 inches wide and deep.




Box #2 is slightly smaller.