Gary,
To a large extent, these are personal decisions. The factory wiring layout
is actually adequate, so you don't really need to add the hassle and extra
wiring for relays, if you don't want to. Of course you'll need to consider
the requirements of any added devices, like your cooling fan & fuel pump,
but they can be met without relays, if you want.
> The AdvanceAuto-wire site
If you want to totally rewire the car with high quality wiring, it's hard to
go wrong with the AAW kit. And it can be installed differently than Dan's
recommendation, to suit your own wants & needs, if desired.
> Should I make the wiring de novo
Well, that has always been my approach, but I am quite comfortable doing so.
If you aren't comfortable with electrical stuff (and don't want to become
so) then a more structured approach may be easier for you, both now and
later.
> The plan is to have a cutoff switch at the dash and inertia
> switch( if
> I can find one) for the fuel pump.
A quick Google shows inertia switches available at Amazon & Pegasus. No
doubt other places as well.
> Is there a simple way to
> wire this through the relay?
Unless you are installing a high current racing (or fuel injection) type
pump, I wouldn't bother with a relay. At the low pressures & flows required
by our cars, the pump just doesn't draw that much current. You can just
wire it to the ignition switch, with the cutoff and inertia switches in
series with the pump.
However, if you want to install a relay ala AAW, then the output of the
relay becomes just like the output of the switch, and you can wire anything
to it. That means the pump current still passes through your cutoff switch,
and inertia switch.
Another approach is to use a purpose-made relay that senses whether the
engine is turning and shuts off the pump if the engine dies. More expensive
than a standard relay, but comparable to a relay plus inertia switch. These
are used on many cars with Bosch fuel injection (my VW Rabbit had one with
an integrated fuse as well).
http://tinyurl.com/ydbkqbf
> The wiring for the fan would be similar
Fans typically draw pretty high current, especially when starting, so I
would suggest using a relay here. That way, only the wiring to the relay &
fan needs to carry the full fan current, the wiring to the dash &
temperature switches can be smaller (and so can the switches).
My preference here is for a purpose-made relay that does more, eg,
http://www.jegs.com/i/Derale/259/16759/10002/-1?CT=999
includes a temperature probe and adjustable temperature. The AC input can
be used for your override switch.
> Should I add relays to the horn and headlamp circuits?
Again, your choice. I had them on my TR3A, and will soon be adding them to
my 'project' TR3. I want the horns & headlights as loud & bright as
possible, and relays help achieve that goal by maximizing the power
delivered to them.
> Any good places to find switches, relays, wire, etc ?
Sorry, I don't have any single place to recommend. I get most of mine from
flea-bay. However, this site:
http://www.madelectrical.com
seems to offer some quality components at reasonable prices. I particularly
like this one:
http://www.madelectrical.com/catalog/cn-1.shtml
although I haven't actually ordered one yet.
Randall
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