Complete rewire using American Auto Wire kit for 1960 to 1966 C10/20/30
 

Step by step tutorial on rewiring our truck. My truck is not stock but this process is identical to how you will do this and with this specific kit it is mostly plug and play. :metal:

So first thing is the unboxing and exploration of the kit. A couple notes

Kit is packaged in an intuitive and intelligent manner with separate packaging for different parts of the truck. The under-hood kit is not in with the lighting. The acc. wiring is separate as some of our trucks don't have any of that, the engine harness is separated from the front half lighting. ;)

here is the new stuff. I laid it out upside down so you can see the stuff in the bags. On the top of each bag is a label and description of what is inside.

Attachment 1779391

Attachment 1779392

I laid out the tools I will need to do the install.

Attachment 1779394

Attachment 1779393

So with no more excuses to delay, I pulled the seat out of the truck and got ready to make my back hurt

Attachment 1779400

Re: Complete rewire using American Auto Wire kit for 1960 to 1966 C10/20/30
 

You da man!!!

Re: Complete rewire using American Auto Wire kit for 1960 to 1966 C10/20/30
 

So Pulled the old carpet and padding out. Took my time to not tear it as it was glued down 25 years ago. It was still in good shape and will have to live a couple more years before I do yet another chassis up build.

Here it is with the carpet out.


Attachment 1779408

I have owned this truck for ever. in that time it has had 3 different stereos installed as well as an alarm system. A new column and several different sets of gauges. None of that was done by me. (Well the column was mine but I kind of cobbed it in too. So the amount of splices, and old dead wires with the ubiquitous electrical tape and zip ties made this truck about as reliable as a meth addict.

see for your self.


Attachment 1779409

Attachment 1779410

Attachment 1779411


here is the instrument panel before I pulled it out. All nice guages and I did do a pretty decent job wiring it all in but it is wired into the original 53 year old harness.

Attachment 1779412


Attachment 1779412

Re: Complete rewire using American Auto Wire kit for 1960 to 1966 C10/20/30
 

Continuing with the demolition.

a couple notes here. Last year I did a head light up grade with new halo LED's with High output LED projectors. I built a new harness and used new OEM plugs tied into the front harness so I need to incorporate that harness into the new Autowire kit. This holds true for the trucks current (4th) stereo as I installed it and did it correctly so it to will be incorporated.


So this is the back of the instrument panel and probably has the most complicated part of this. For the folks with a stock truck this is all plug in with the new harness.
Attachment 1779419

this is looking in at the rats nest once the instrument panel is out.

Attachment 1779420

Yikes I found several smoked and crunch connectors in here from previous shorts it is a wonder I did not burn this truck to the ground,


damn how embarrassing. I can't believe I am letting people see this.


so the under dash is demoed, I will get in and clean up some stuff as well as mount a couple anchor points to hang the new harness.

Attachment 1779421
Attachment 1779422

I have a MSD ignition box mounted under the dash that needs to be wired in as well as putting in new defroster and heater ducts.

Re: Complete rewire using American Auto Wire kit for 1960 to 1966 C10/20/30
 

Good deal I’m following!

Re: Complete rewire using American Auto Wire kit for 1960 to 1966 C10/20/30
 

Brilliant!!!!!!!!

Re: Complete rewire using American Auto Wire kit for 1960 to 1966 C10/20/30
 

yep this is one to follow for me, got the same kit and have been dreading it. Wiring is the lowest of my skill sets.

Re: Complete rewire using American Auto Wire kit for 1960 to 1966 C10/20/30
 

i got the same kit last year , it wired right up , good directions, and illustrations, would defiantly buy another autowire kit if i ever had to do it again to another truck

Re: Complete rewire using American Auto Wire kit for 1960 to 1966 C10/20/30
 

How much money does this kit run?
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Re: Complete rewire using American Auto Wire kit for 1960 to 1966 C10/20/30
 

Haven't seen an soldering iron like that in a very long time.

Following as I will be doing this in the summer!

Re: Complete rewire using American Auto Wire kit for 1960 to 1966 C10/20/30
 

I used the same kit on my 64 and my 65. Was real easy to install.

Re: Complete rewire using American Auto Wire kit for 1960 to 1966 C10/20/30
 

https://www.americanautowire.com/sho...66-chevy-truck

Figure $600 and some change after taxes

Re: Complete rewire using American Auto Wire kit for 1960 to 1966 C10/20/30
 

$530 no taxes - https://www.ebay.com/itm/1960-66-Che...sAAOSwhj9aj3Qa

Re: Complete rewire using American Auto Wire kit for 1960 to 1966 C10/20/30
 

which set is this from american autowire?

Re: Complete rewire using American Auto Wire kit for 1960 to 1966 C10/20/30
 

This is the 500560 it supersedes the 500559 with more circuits available.

Couple notes for the hot rodders on here.

If you have aftermarket gauges this kit has a complete separate set of leads already marked to wire into those gauges.

If you have aftermarket heating and AC this kit has outputs for that too.

People with stereo systems. Yep, kit has leads for head units, amplifiers and even multiple Acc, all fused and ready to hook up.

My specific application will need a day time running light output that is switched with the ign. Oh boy that is plug and play and even marked with its very own fuse.


I talked to the nice people at Painless and they do offer a simple "builders" harness but nothing like this kit.

I paid just shy of 6 bills direct from American Autowire and they shipped it with a DVD and it was here in 3 days. I spoke at length with the tech support staff before placing my order and they were very informative and instructed me on every aspect of the kit. I hope I can muddle through this install without bothering them again but they are there waiting if needed. :metal:

Re: Complete rewire using American Auto Wire kit for 1960 to 1966 C10/20/30
 

A detailed wiring thread has been much needed. Will follow this very closely.

I think many of us are in this boat and not eager to tackle a full rewire. I have heard that the AA kit is excellent and very doable for the average guy.

Re: Complete rewire using American Auto Wire kit for 1960 to 1966 C10/20/30
 

Sub'd
Thank you Mr. Haas

Re: Complete rewire using American Auto Wire kit for 1960 to 1966 C10/20/30
 

One step I am taking as it is the perfect opportunity is to clean up the floor and spray some rust inhibitor on any exposed rust or bear metal. So we cleaned up the floor, and sprayed it with some "Flash" aerosol sealer. It is like POR15 but faster. Attachment 1779665

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that out of the way it is time for the sound proofing material

You could use dynomat or what ever, I have a commercial product that we are putting down.

Attachment 1779668

Re: Complete rewire using American Auto Wire kit for 1960 to 1966 C10/20/30
 

So the sound proofing is finished. A lot harder then I thought it would be to be honest but it is important and should keep some heat out of the cab as well. Attachment 1779701

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Re: Complete rewire using American Auto Wire kit for 1960 to 1966 C10/20/30
 

How many packs did you use?

Re: Complete rewire using American Auto Wire kit for 1960 to 1966 C10/20/30
 

5 of the 6

Re: Complete rewire using American Auto Wire kit for 1960 to 1966 C10/20/30
 

I am in for this

Re: Complete rewire using American Auto Wire kit for 1960 to 1966 C10/20/30
 

After demolition and matting is completed we went ahead with the panel installation..

The kit supplies a mounting plate and hardware.

remove 2 upper fender bolts and replace with longer ones, (one at a time)

Attachment 1780282

changing from this to this

Attachment 1780284

installed

Attachment 1780283

from the inside you can see how they are now ready to act like studs to hang the panel on.

Attachment 1780286

then hang the panel

Attachment 1780287

Re: Complete rewire using American Auto Wire kit for 1960 to 1966 C10/20/30
 

There are a couple new hangers in the kit to hold the harness got those in and started tiding up the loom
Attachment 1780288


If you are doing this on an unmolested original truck it is really a matter of plu and play for 90% of the kit from this point.

We are not so lucky as I have aftermarket instruments, ignition, headlights and stereo.

The kit is designed to bring all of that into use with dedicated wiring and fuses for each system.

Here is the back of my instrument panel.

Attachment 1780289


It has lots of stuff I did to make it work with the old system that I will now cut away and do using the new harness. For example the new harness has instruments lighting as a dedicated circuit that works with the supplied switch with a dimmer, something the original sort of had but didn't work. Also I will now use the new harness to supply signals for the water temp. Volt meter and Tach all that were dedicated loose wires before. The new harness has these leads and they are marked on the wires every 6 inches so future modifications will be so easy.

Re: Complete rewire using American Auto Wire kit for 1960 to 1966 C10/20/30
 

I really appreciate you taking the time to show this. I will be at this phase of my rebuild sometime this year and actually it intimidates the crap out off me. I do appreciate the " if original it is more plug and play as mine is original .. might lower my stress level .

Any additional insight on parts/accessories/tool to buy to help with the process would be appreciated. :metal: