A recent thread got me thinking that its probably time to start collecting products to make engine harnesses. My girlfriends t2 hasn't been running for months due to what I believe is a poor engine harness, and I'm going to need a custom one for my build as I'm on the home stretch with that.

Lets talk about the tools and products necessary to completely remake a wire harness like a pro.

Searching other threads, I found mil-spec wire that comes in a variety of colors, purchasable by the foot. 22 GA-Prowire USA Any ideas of what gauge wire I should use? Is there a tool to measure gauge?

This company has shrink tubing in 2:1, 3:1, and 4:1 ratios. Purchasable cheaper than I've been getting it, and purchasable in small quantities. I already have a heat gun. Heat Shrink Tubing Seals Automotive Connectors - Waytek, Inc.

What do you guys recommend? Sheath or split loom?

What type of crimps are used? Are they "F" type? Terminals/Pins? Hand tools?

I'll update as I search more later. I'd like your input too! Please hold the "just reuse the existing brittle wire" or "bullet terminal dat bitch" comments.

 

Prowire, mentioned before, also has heat shrink boots. Might be useful.? Raychem-Prowire USA

 

I've been using a nice scissor style wire stripper for years. I think this project requires a pair of strippers that will work flawlessly and strip to a predetermined length.

Runner ups



My decision


Amazon.com: Klein Tools 11081 Adjustable Wire Stop for Katapult Wire Stripper: Home Improvement


I purchased the klein katapult automatic strippers. Lots of reviews online said that they are professional grade. The blades are even replaceable. The self adjusting ones tend to not work as well with stranded wire, so says a few comments I read. I found out that these strippers have a stopper sold separately. Perfect. Amazon was out of stock on the stopper, so I purchased the tools at ktools.net. $33 doesn't seem bad for a quality tool I will use often. I've installed car stereos, and fixed stereo installations from best buy when friends call saying their dash is smoking. Free installation, huh? Lol

 

You'll need something like the Klein to strip Tefzel mil wire. The self adjusting type will not work.

 

Awesome. That's what I purchased.

Any advice on what type of terminals (pins) are used, and a racheting crimp tool?

 

Sounds pretty good so far. I'm interested to see where you get the connectors for the harness and which ratcheting crimp tool you get.

 

Thanks! I have 1 or 2 extra engine harnesses for reference and connectors. Some connectors will be salvageable. I think I might use weather pack or similar connectors on my girlfriends O2 and where ever else I see fit. Some connectors are unique and mazda sold the last S4 T2 harness last year I believe. I remember seeing a thread about it. I don't need an O2 for my harness, as I'm running a powerfc with wide band. I also have ID injectors, but stock injectors and the water pump sensor are easy to find replacements.

Anyone know where to find some of the hard to find ones, post up! I hope this will be a great thread for all of us. If all works out well, maybe I'll consider making some for others since Corksport no longer makes them.

 

You won't find anything in particular about the engine (emissions) harness for the FC chassis on this page. But there's some part numbers at the bottom of teh page for chassis harness parts in various forms.

FC Race harness


It's my page left over from my business converted to just free info for anyone that needs it. I do have some factory IAT connectors and terminals, and I can give you the parts numbers for almost every connector on the engine (emissions) harness if you need direction.

Best to holler at me on my FB page I don't come here often. Or better yet email me at rotaryrelated@live.com then you can repost the part numbers here if you like and the links to buy them at. I just haven't had an opprtunity to add anymore material to the site in awhile. I have 95% of the part numbers for a FC already. I have some connectors left as well from when I was manufacturing harnesses.

Somebody on my FB friends list alerted me to this thread if your wondering. There's lots of other useful stuff on the site if you play around with it. For some reason Iphone's can not display the html of teh page correctly, so just a heads up.

 

Thank you! I'll definately check out that link, and ask you any questions I have at some point. PS I'm Keil Miller Jr on facebook. Already a fan!

Ordered the rest of the tools I believe I need. Even if some are not required, I think they will make this and other projects in the future easier. I still want to order a new digital caliper some time as my harbor freight one is mia and I use it all the time for various things.

• Channellock 436 6-Inch Diagonal Cutting Plier - Amazon.com
  Channellock 436 6-Inch Diagonal Cutting Plier - Amazon.com
• Amazon.com: Sir Tools (SIRST9025) Fold-Up Wire Terminal Extractor Kit with 12 Barbs: Home Improvement
  Amazon.com: Sir Tools (SIRST9025) Fold-Up Wire Terminal Extractor Kit with 12 Barbs: Home Improvement
• General Tools 20 American Standard Wire Round Gage - Amazon.com
  General Tools 20 American Standard Wire Round Gage - Amazon.com
• Open Barrel Terminal Ratchet Crimp Tool

Next step is determining which connectors/components I need, sourcing new connectors.

 

I wouldn't spend $40 on the extraction tool. Most connectors you can depin with a good jewelers screwdriver. You'll need a Weatherpack tool, if you want to work with those. I'd avoid Weatherpack all together though, if possible. The AMP JPT connectors used on most Bosch stuff (EV1 injectors for example) are easier when you have the correct 2-prong tool, but you can do it with a pair of screwdrivers. If you're only doing a couple harnesses, I wouldn't expect to invest hundreds in tooling you might not ever use again.

The open-barrel crimpers from Del-City are kind of crampy. They'll work, but here is an occasion you get what you pay for.

We have most of the connectors you'll need for a single harness build. Have several we just started stocking that aren't on the website. Most of the important stuff on the FC is Sumitomo. On the FD Sumitomo and Tyco/AMP. There is a good thread in the 3rd gen section that lists part numbers for just about everything on the 3rd gen emissions harness.

 

@C Ludwig is there a crimp tool that you recommend? I got them because they were the only open barrel crimpers that I could find that actually said that it crimps both the wre and insulation at the same time. No one posted in this thread with any recommendations for crimpers yet.

Here's a picture of the tools I acquired. Good tools should make the process easier to do a clean job. I'm excited. This weekend I'll start on the hunt for connectors. Have to take out an oem harness and see what we need.

 

Tuscanidream
Any updates on your harness? I'm looking to doing the same thing and wanted to know what you came up with as for wire gauges and connectors.