Engine Wiring 101

[Fendamonky]

Originally Posted by Rotary Evolution

i always prefer a new harness over an old one but the following are steps i use to buy more life from marginal, old, original wiring:

For the purpose of this thread lets assume that all wiring is new, there are no reused connectors, and we're not splicing into a pre-existing wiring harness.

Assuming we're working with the initial items of several different spools of wire brand new connectors, and brand new ECU outs with short (if any) leads.

Originally Posted by Rotary Evolution

the biggest thing about wiring isn't so much the wire but the wire insulation. after years sitting in a 200F engine bay the insulation gets brittle and cracks, exposing the wires where they will begin to fray and oxidize. new wire is always preferred so that you can buy many more years before it begins to do the same.

What, specific, insulation are we looking for in the wiring? What are the good options, the bad options, and the "wtf is this doing in a VEHICLE??" options?

Originally Posted by TitaniumTT

Marginal wiring is a popped engine waiting to happen...

With this in mind Brian, what would you suggest as the shopping list prior to attacking the chore of building a harness from scratch?
Obviously you're going to need wiring (suggestions on a specific brand or style to look for?), Connectors (as applicable to your individual setup), Environmental Protection (Raychem and heat shrink, to keep the wiring protected and organized: Any suggestions on specific types and specifics?), and a way to attach the wires to the connectors (suggestion on specific crimps that are worth getting, or confirmation on the one Whoop suggested, types to look for and/or avoid, etc., etc.)

Originally Posted by Not-so Angry Brian

ALL electrical tape is unsuited for an engine harness.... that is all. PERIOD! If you have a wire that's been compromised, cut it, cut it back, strip it, apply some adhesive lined heat shrink, crimp it, and heat it.

I would assume the electrical tapes primary use would be for bundling wires while sliding the main sheath of raychem over the whole harness

Originally Posted by Brian

Good luck bundeling those massive things. Don't forget either, if you use the wrong crimpers you'll slice the massively ginourmous heatshrink and it will just peel back exposing the crimp. I use those in one place and one place only, maring wiring because they are required by the CG, other than that, they are fucking trash... expensive trash to boot.

What would be the correct crimpers to use in an instance like this?

Originally Posted by Brian

Buy the right tools, buy the right crimpers, plan it out, do it once, don't repair shit, there should be zero butt connectors in an engine harness, take all your electrical tape and throw it away when you're building a harness unless you're using it to temporarily bundle wires, Raychem is your friend, spend the money, like levi said though, unless you're planning on doing a few of these, have some different requirements, or just want to take pride in your work, there are better alternatives.

I know this is just a repeat of my previous replies, but would you go into more detail regarding what ARE the correct tools and supplies to use? (I know you've got plenty of stuff going on that takes priority, but if you could expound on the right stuff verses the wrong stuff that would be fucking awesome!!)

Originally Posted by Brian

I've seen rywires and while they aren't the greatest of fitting harnesses, they use tefzel, they use Raychem, they use adhesive lined heat shrink... I have no idea how they build them as cheap as they do.... for me to do a fully custom engine harness with the bulkhead connector and wire in an ecu and get the car started, you're looking at ~$2k.... but..... at the end of the day, it will last longer than your car and you'll never have to worry about it.

My guess is that they buy their supplies in bulk, and they just have jigs made up so it's stupid easy for them to kick out looms after the first one is made..

Originally Posted by Bri-face

Now.... I'm going to throw feces at a certain green jeep......

This wouldn't happen to be that one I found... would it??

Originally Posted by RICE RACING

Two words:

SCOTCH LOCKS!

Quality ECU instal harness NOTE: wiring conduit = professional = Australia #1 ECU for rotaries = WINNING!

Not sure if you're having a laugh here . Because, well... I don't know much (read: anything) about wiring, but that seems a bit off to me... lol

[Kontakt]

Originally Posted by Fendamonky

With this in mind Brian, what would you suggest as the shopping list prior to attacking the chore of building a harness from scratch?
Obviously you're going to need wiring (suggestions on a specific brand or style to look for?), Connectors (as applicable to your individual setup), Environmental Protection (Raychem and heat shrink, to keep the wiring protected and organized: Any suggestions on specific types and specifics?), and a way to attach the wires to the connectors (suggestion on specific crimps that are worth getting, or confirmation on the one Whoop suggested, types to look for and/or avoid, etc., etc.)

Next time I see him, I'll try to remember to bring my Tri-Crimp, and see about getting an opinion on it. I have no idea how common they are outside of the radio nerd crowd.