After some Guidance on how to route wiring in my example?

[askitee]

A few years ago, I added a set of driving lights to my RTL, then later a trailer bypass relay and some cameras.

Overall, the setup works great, but there are two issues I haven’t been able to fully solve:

1. The messy “rats nest” where all the project wiring converges at the ground/fuse block/relay area.
2. Occasional water getting into the relay area — is there a reliable way to waterproof relay housings and their connectors? (I took a shortcut and sprayed Flex Seal over the fuse block housing leaving a "window" for the fuse block status LED.)

For those with experience designing and building custom wiring looms - what principles or logic do you use to keep things tidy and protected that I might be missing?

Before running the cables, I thought through a few lessons learned from earlier setups:

• I made sure the lights could be easily disconnected for bike servicing.
• I routed the cables away from sharp edges or objects.
• I used waterproof connectors wherever possible.
• When I had to use crimp connectors, after crimping I sealed the wire entry points with liquid electrical tape.
• I zip-tied the wiring looms securely to protect them from vibration or movement.
• I installed a mini fuse block to draw power from the battery, with an inline fuse on the feed line to it to protect against things like water flooding the fuse block.
• I also created a common ground/earth point, which later served additional gear like the camera and trailer supply.

I avoided photos as I was hoping to get the "concepts" of when you guys look at a wiring job and say how you attack a task. I tried to think of the problems I would encounter by walking thru it and was able to address most but the last two.

• Do you group/bundle wires from the left side together or does that create a problem at disassembly? Ditto for the right?
• Do you add connectors at certain points to facilitate disassembly
• As an example - the Camera recorder is under the seat, Driving Light relay under the fairing, trailer bypass relay is in the tail.

 

[chipveres]

It sounds to me like your thinking is "on the beam" and ahead of 99% of people who consider themselves electricians. My only contribution is to say that I would much rather add a wire to an existing harness than make up a new one. But I have done it both ways.