building my own wire harness

I redid a harness for my charger years back when no aftermarket harnesses were available. First, I used a wiring diagram to make sure I had the correct gauges of wire available. Second, I unwrapped the original harness back from the plugs several inches and cut the wires offsetting the cuts so all the new connections would nor overlap and create a thicker spot in the harness. Third, I laid the old harness (minus the plugs) on the floor and started laying replacement wires on top of the old harness to make sure routing was correct and the wires were long enough (make sure you leave plenty extra at the plug ends). Fourth, I used short wraps of electrical tape at each of the spits to ensure that the new harness would be dimentionally the same as the old one and to prevent a tangled mess. Fifth, I solderd the tag ends of the wires left on the old plugs to the new harness. Make sure you slip shrink wrap connectors in the wires before you solder them together, then heat the connecters to insulate the newly soldered joints. Finally, I rewrapped the harness with electrical tape (you might need to find old style cloth tape AKA hockey tape if your old one came that way). Make sure you use a continuity connector to check each of your new connections (from plug to plug) before you wrap everything up. All in all, it took an evening with my wife's help, and 20 years of her reminding me not to ask her to help me do it again.

My wife just reminded me to add one more instruction ... try to find the replacement wires not only in the same gauge, but in the same colors if you can. I used only a few rolls of wire so had to be really carefull not to mix up or cross wires.

Good luck!