Have to thank Dysonman for taking the time to upload pic and provide written description of connections. As a result, a 7850 purchased long ago but used very little is back to life. Thank you, sir!
Figured I'd throw a few pics up of what the original "job" looked like.
The first picture was taken after I cut the power cord a few inches up from original splices, stripped additional shielding, then ran the two individual wires thru the channels included on back of wiring harness support. The cut PC wire is in background (black & white) dangling ready for new connections. The wire nuts show the remnants of the old connections.
On the right, the black PC wire was joined to a short black wire that connected to the switch. The two wires were apparently not twisted well (neither the unshielded copper connections, nor the shielded wires), and no electrical tape was used. Likewise, the individual PC wires were not run thru the wiring harness support channels (which I assume exist to keep any tension from cord tugs, e.g. when vac gets to end of cord reach, away from actual wired joints). As a result, any tug on the line was a pull directly on the wire joint (there was no other type of stop). What's unclear in this picture is the origin of those bare copper wires - they did not come from that joint.
Which leads to the joint on the left. This was originally the joined Full Bag Light wire + Power Cord wire + Motor wire. Again, not twisted exceptionally well, no electrical tape (if you're too lazy to throw some electrical tape on there, find something else to do), and PC wires not channeled. What was odd was, it appeared that the black PC wire was spliced at the the connection on the right and joined to the connection to the left (white PC wire was hanging, unconnected, and bare copper was fused between connection on L + R). So, wire wasn't fastened very well, PC wasn't run thru channel, tug on wire was a tug directly on joints, wire worked loose, and and bare wire fused together across connections producing spark city.
Sweet.
Anyhow, the next pic shows the re-wire.
PC strands are run thru wiring harness channels so a tug on the wire produces tension on the individual wires between the two middle plastic tabs and the tabs themselves and not on the weak wire joints instead (assume that's the intent of the channeling... if not, it's been re-purposed!). The individual connections are nice and snug (thanks to dysonman, connected to the right wires too!), and electric tape co. stock should spike. Which means this thing (3rd pic), which really saw very little use given two power cord fails in a short time after purchase, has some life to live.
Thanks again, dysonman! Now, if I could just get it to stop pulling to the right (and find one for downstairs).
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