How To Install a ZR-1 fiberglass rollpan and wiring harness(2nd gen)

[BlazinLow_inORE]

ZR-1 Rollpan and Wiring Harness

http://www.buildyourride.com/98s10/zr111.jpg

Well here's the rollpan, its fiberglass and came from the factory with a very smooth gelcoat finish. The first thing to do was sand, prime and paint.

http://www.buildyourride.com/98s10/zr109.jpghttp://www.buildyourride.com/98s10/zr108.jpg

These are the lights that were used. Instead of paying around $100 for a ZR1 wiring harness i decided to make my own. The bulbs and bulb sockets came from some readily available trailer lights. In the left picture you can see the trailer light with the lens removed, then with the bulb socket removed, and finally with the mounting bracket cut down. In the right picture you can see how the long bracket was cut smaller and a 1/4" hole was drilled in it.

http://www.buildyourride.com/98s10/zr107.jpg

Next a couple holes were drilled in each bucket. One 1/4" in the center to mount the bulb bracket and and a smaller hole to run the 2 wires from the bulb through.

http://www.buildyourride.com/98s10/zr106.jpg

Here's a bad picture of the bulb bolted to the rollpan and the wires run through the small hole.

http://www.buildyourride.com/98s10/zr105.jpg

This rollpan is installed like any other fiberglass rollpan. (http://www.buildyourride.com/s15pan.html)

[BlazinLow_inORE]

http://www.buildyourride.com/98s10/zr104.jpg

The wiring harness was made from a few common parts. First, available from Walmart, is a universal trailer wiring kit. This kit came with both the trailer and vehicle side of the harness and also some quick splice type connectors. Second some primary wire, crimp connectors and ring terminals were used too. Here you can see half of the harness, each bulb needs 3 wires, a turn/brake, tail, and ground wire. The ring terminals are the ground.

http://www.buildyourride.com/98s10/zr103.jpg

This is how the wiring harness connects to the back of the rollpan. The yellow and brown wires are coming from the bulb. The bolt and nut are holding the bulb bracket to the pan and is also doubling as the bulb ground.

http://www.buildyourride.com/98s10/zr102.jpg

This is a picture of the inside driverside frame rail at the very back of the truck. The white connector on the left is connected to the tail lights. The white connector on the right is connected to the brake switch and turn signal lever. Notice I have disconnected them from each other so the factory tail lights won't work. The wiring harness from Walmart comes with some splice connectors. They are the dark blue connectors in the picture. The colors on the truck harness are as follows:

Yellow - Left Turn

Dark Green - Right Turn

Brown - Tail Lights

Black - Ground

The trailer wiring harness colors are the same exept the white wire is the ground. After hooking up the wires and plugging the harness together, there is nothing else to do except fill in the factory tail lights.

http://www.buildyourride.com/98s10/zr101.jpg

[BlazinLow_inORE]

courtesy of...http://www.buildyourride.com/s10zr1.html