From: Ron Paitich Date: Fri Dec 26, 2003 10:30 am Subject: Re: [subaruvanagon] Best Method of Connecting Wires in Harness? ADVERTISEMENT Brent, I work in electronic instrument design; I used the same practice in modifying my Subaru harness that we use in electronics work: solder and heat-shrink tubing. This makes for neat and reliable connections. I agree with you; repair of automotive electrics is irritating and usually difficult to get to. I try to make any modifications bullet-proof. I use a temperature-controlled soldering iron; these are around $100. I also have a commercial hot-air gun for shrinking the heat-shrink tubing. You should be able to buy all supplies needed at your local Radio Shack or Fry's Electronics. * I discarded the unneeded parts of the harness, as defined in KEP literature * I tagged the wire ends that would be soldered later with matching numbers; this allowed me to route the wires more freely into the best position. * Strip about 3/4 inch of insulation from each of the wires * Slip a piece of 1.5 inch heat shrink over one of the wires; I think I used 1/8-inch heat-shrink * Twist the two wires tightly together * Use rosin core solder and a soldering iron with small tip (I use a cone tip, 1/16-inch diam), set to about 700 degrees F. * Heat the wires with the soldering iron, then apply solder. Flow solder until the entire joint, top and bottom, is "wetted" by the solder; be careful not to jiggle the joint while the solder cools. * Slide the heat-shrink over the solder joint and apply hot air from the heat-shrink gun until the heat-shrink tubing is snug around the solder joint. Be careful to position the heat-shrink in the middle of the joint, so you don't have any bare spots. * When done, use zip-ties to secure the bundles of wire in the proper position for the harness * After the zip tie process, I'll use some spiral wrap cable cover to make it all tidy; I'm not sure if Radio Shack will have this. If you have a Fry's Electronics nearby, they'll have it. Call if you like: 530-269-2966 Ron '86 Syncro '91 EJ22; harness almost done (!) From: "Lawrence Hagaman" Date: Fri Dec 26, 2003 12:37 pm Subject: RE: [subaruvanagon] Best Method of Connecting Wires in Harness? ADVERTISEMENT Hey Brent, Many potential future wiring problems can be minimized with good electrical connections. Two things we know about automotive wiring, the wiring is subjected to vibration and moisture. Therefore the best possible connections are desired. Here are my methods for making wiring connections passed on to me by an old mechanic. They may seem extreme, but in thirty years I have never had a connection failure. I believe in doing things right the first time (if possible). After you get the hang of it and a system going, the time and money spent is minimum. Wire to wire inline connection: 1. Cut a length of heat shrink to extend pass each end of the exposed connection. Heat shrink is cheap when looking at the overall cost of the conversion, so I allow about ½” on each side, plus about ½” for the connection (total 1 ½”). 2. Slide cut heat shrink over one end of a wire; now cut the insulation off of that wire (about ½”). 3. Cut the insulation off of the other wire (about ½”). 4. Typically the individual strands of the wires are twisted. Un-twist to straighten the individual wires. Now spread the individual wires apart slightly. Do this procedure for both wires. 5. Take the two wires ends and slide together until end of one wire almost reaches insulation of the other wire, individual strands will be intermixed (lack of better word). Now pinch this connection together and put slight a twist in the connection (this will hold the connection together). 6. Make sure the heat shrink is a good distance away from the connection and solder the connection. 7. Let connection cool, and then slide the heat shrink over the connection and center (heat shrink should extend past each end of the soldered connection). Apply heat to heat shrink and your done. Wire to male/female connection with protective cover: 1. With a pair of needle-nose pliers, pull metal male/female connection out of protective cover. If you have a problem doing this, here is a easy method. Drill a hole in a piece of metal, slightly larger than the metal connector, but smaller than protective cover. Mount piece of metal in vise. With needle-nose pliers, reach through hole and grab metal connector. Now pull down with pliers. Metal connector will slide out of protective cover. 2. Cut a 1” piece of heat shrink that is slightly larger than the wire. Cut a 1 ¼” piece of heat shrink that is slightly large than the collar of the protective cover. 3. I use a drill bit to widen the hole in the collar of the protective cover to slide over the smaller heat shrink. 4. Now slide “large” heat shrink, then protective cover, then small heat shrink onto wire. 5. Cut length of insulation off wire to match collar of metal connector. 6. Slide exposed wire into metal collar and crimp slightly to hold. 7. Make sure the heat shrink is a good distance away from the connection and solder the connection. 8. Let connection cool, then slide “small” heat shrink up over soldered/crimp connection and apply heat. Slide protective cover up over metal male/female connection. Slide “large” heat shrink up over collar of protective collar and apply heat, your done. This connection method has never pulled apart you me. My two cents, hope this helps, Larry Fastvanagon From: glmcen@n... Date: Sat Dec 27, 2003 5:58 am Subject: Re: [subaruvanagon] Best Method of Connecting Wires in Harness? ADVERTISEMENT The only thing I might add to Ron's excellent wiring instructions is to stagger the solder joints so that when you are through there isn't a big thick spot in the harness. This also reduces the likelyhood of shorts. I like to avoid use of the "butt" style crimp connectors because of concerns of reliability particularly when making so many connections. Solder joints are less expensive and can be more easily "visually" verified for reliability than crimp connections. Gary Gary McEachern Reading, Ma '90 Westy Subavanagon '86 Wolfy Subavanagon From: "Norm Hoffman" Date: Fri Dec 26, 2003 6:20 pm Subject: Re: [subaruvanagon] Best Method of Connecting Wires in Harness? ADVERTISEMENT Brent, Get some heat shrink tubing in different diameters and use them over the SOLDERED connections. Also get a couple rolls of electrical tape (like a couple of BIG rolls) to wrap the harness. I digital volt/ohm meter with an audible continuity checker is a great toy to have for verifying connections. And remember to back probe the connectors where possible to check a circuit. If you front probe too deeply with too fat a probe you can spring the connectors inside their shells making for intermittent opens at the components they plug into. Happened to me when I did my harness. The thing you'll need in the largest quantity is time. Don't rush it and verify all the connections. Norm From: "Chuck Fiero" Date: Mon Dec 29, 2003 1:56 am Subject: Re: [subaruvanagon] Re: Best Method of Connecting Wires in Harness? ADVERTISEMENT Gary--having recently rewired a house originally constructed with aluminum wiring, I found two problems with aluminum to copper connections (I'm assuming your alternator wires are copper) first the corrosion resultant from connecting dissimilar metals really does occur producing high resistance junctions, and second aluminum pressure connectors (set screws in the aluminum sleeves)dont work- the more vibration, the quicker the pressure relieves. I'm guessing that copper sleeves would work better even if you have to go to an industrial strength two handed crimper. There is a blue paste available for use with cu/al pressure connections but I personaly dont think its effective. Best wishes Chuck JOINING WIRES in my testing i did several reconfigurations my final setup is that i only used the connectors and pigtails from them. i soldered in the extensions that i needed and heat shrinked a double wrap over each soldered joint. all areas that i used crimp connectors were doubled back and heat shrinked. i also used split loom tubing over all stretches and used colored electrical tape to wrap those sections. this leaves a harness very similar to the factory harness but in the correct length for where you want the ECU, relays, and ignitor. in my case hidden under a false bottom shelf in the bottom of one of my westy cabinets. note that a total redesign like this may look very daunting to some but is actually quite simple. jimt From: Ron Paitich Date: Mon Dec 29, 2003 9:49 am Subject: Re: [subaruvanagon] Re: Best Method of Connecting Wires in Harness? ADVERTISEMENT Gary makes a good point: solder does stiffen wires; as he says, this could result in failure under some conditions. The way I soldered my harness, the soldered connections are bundled into a larger bundle that effectively eliminates any flexing of the solder joint. Vibration will not be an issue if the physical excursion the wire makes is small. With crimp joints, you'll need to be careful that the joint is not subject to flexing also, because the crimp fastener effectively stiffens that part of the connection. Excessive vibration can adversely affect crimp connections as well. If you use any wire to splice harness wires that are too short (like the Battery and Ignition On), be sure to use stranded wire. Under the same conditions, large diameter (10 AWG to 14 AWG) solid wire, as used in home wiring, will be more likely to break than stranded wire with vibration and flexure. A continuous stranded wire is the best choice; I like soldered connections with stranded wire as a close second. Ron