I'd like some advice on wiring maintenance / repair. I'm finishing up my hose job and am laying the wiring harness back in place. The tape and shrink covering is just crumbling off of the wires. So questions... (I searched and am amazed to not find this discussed...?)

- should I re-wrap the wires? Shrink tubing is not an option since I can't / don't want to attempt removing connectors from brittle wires. Is there a preferred tape to wrap with? I fear standard electrical tape will just turn to goo in the heat and make a mess of the wires.

- if a wire itself breaks or its insulation crumbles, what are my options? Must the entire wiring harness be replaced? Given the fragile state of the wiring I don't think the existing wires could be spliced / joined.

- how much is a new wiring harness? <bracing myself>

 

www.mcmaster.com : silicone rubber self-fusing tape. (catalog page 3189). I think a couple rolls of the .020 rectangular ought be enough to do the entire harness. McMaster-Carr ships VERY fast.


That was what I used to rewrap my harness and although wrapping is a little tedious, it's probably the easiest. I overlapped it half so that there is a continous 2 layers thick for thermal insulation. If you can, I suggest getting a helper so you have 2 hands to handle the tape.

Came out REALLY well. I was surprised.

New harnesses are $650. Not worth it unless you connectors are breaking and your wires are getting high resistance.

Dave

 

Dave, thanks. That stuff looks great. I wonder if I can find it at a local auto parts store? Worth a try. Did you unwrap/cut the old brittle stuff first?

 

I just did the same thing because i think it was he who reffered me to the silicone wrap, it's amazing. Strip your harness down the the wires, lay it out where they plugs have to go on the engine then just try to tape up the harness going around twice making a band about every 6 inches. I did this then did the whole silicone wrap thing. I don't know if im just gonna leave the silicone exposed or if im gonna use the high temp wire loom that i have in the garage. Defintely a good choice for the heat protectant tho.

As far as brittle wires go.. you can trace them back to where the rubber grommet/ boot is that protects the harness frm going through the firewall and waterproofs everything, this area is not as subject to being brittle from heat, so if you must trace the wire to here and cut, solder, heat shrink and do the same for the connector. There actually is a link for this tho.


https://www.rx7club.com/showthread.p...t=manipulation

 

iluvmy3rdgen: I'm glad it worked for you too.

Auto store: no. Electrical supply store, maybe. Mcmaster is a little pricey, but they will get it to you on Tuesday if you order today. They have regional warehouses that keep shipping times down.

Dave