I made a lot of good progress on the wire list yesterday... I ran out of time for the day, but I'm to the point at which I can start filling in prices and vendor links for connectors, connector accessories (TPA/"Secondary Lock", caps, lids, latches, Shorting Plugs, etc.--things that go according to the quantity of a given connector I use in the harness), terminals and terminal accessories (a convenient category that lets me use the same column as connector accessories... it's really just cable seals for terminals used in sealed connectors). I need to filter the list of terminals a little bit to be sure I'm not using one of one gauge of terminal when everything else is a different gauge... or if I am, there's a good reason.
I have more ground to cover on the wires. I can use the same spreadsheet magic to sort out unique combos of color and gauge, then count the instances of those unique combos. I'm sure I'll do a good bit of filtering here, as GM throws in a lot of striped wire that I don't really need. I will probably adjust the color codes on a circuit-by-circuit basis to make sure that I'm not ordering an entire spool of a particular combo for one circuit that's 14 inches long.
When the Great Wall was being built, a Chinese general contracted with an engineer to build one of the fortresses. The engineer designed the fortress, calculated how many bricks it would need, then placed an order for that many bricks. The general asked if the engineer should order a few more bricks, just to be safe. The engineer ordered one more brick. To this day, that brick sits on a table in the fortress.
That's my goal in this exercise... place ONE order with exactly what I need to build the harness from scratch to the maximum extent feasible.
However, that applies to the connectors, terminals and wire. I already expect that I will build and route the harness, THEN add up all the DR-25 that I'll need to dress it.
My stretch goal is to do all this well enough and plan out the system checks--like verifying fuel pump and relay function--that the engine starts and runs first crank.
[This message has been edited by Will (edited 09-06-2022).]