How to build wiring/harnesses?

[WestlakeHorn]

Consider using weather pack connectors where appropriate. That’s what I’ve been using for my Aux wiring lights on my Raptor. They are durable and work really well.

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[Ajzride]

If you want to see an impressive harness build, check out this thread:

https://thefactoryfiveforum.com/sho...-Harness-Venture&highlight=motorsport+harness

 

[GEN14OWNER]

Never rely solely on a "crimp".

Always solder.

Crimps are fine for stationary harnesses (in building) but anything that is moving... follow up with solder.

 

[personalt]

Never rely solely on a "crimp".

Always solder.

Crimps are fine for stationary harnesses (in building) but anything that is moving... follow up with solder.

In the marine side I have heard the opposite. That the solder connectors can be more likely to fail from vibrations etc and good crimps are recommened connection method. That being said I use the solder seal connectors cause I like them too

 

[Ries]

Lots of good info given here.

-Right tools for the job
-right wire for the job (type (gxl,txl,sxl…) and size AWG)
-Right terminals, seals, and connectors for the job.
-vehicle wire schematics to see what you’re interfacing with.
- a robust plan and schematic for what your going to build. Harness boards anice

 

[imnuts]

Never rely solely on a "crimp".

Always solder.

Crimps are fine for stationary harnesses (in building) but anything that is moving... follow up with solder.

In the marine side I have heard the opposite. That the solder connectors can be more likely to fail from vibrations etc and good crimps are recommened connection method. That being said I use the solder seal connectors cause I like them too

VW/Audi states the same thing regarding solder for wiring connections. It shouldn't be used as the solder connections creates a point that is more likely to fail. I would guess that the lack of flexibility at the solder point makes it flex more just before/after which can lead to the failure. If it's on a terminal going into a connector, that likely isn't as big of an issue, but would be if the connection is in the middle of a wire run.

 

[Ajzride]

Factory connections are not soldered and good quality double crimped connectors (Not the junk you buy at AutoZone) do not need to be soldered. Soldering does in fact make the connection more brittle, but lots of people insist on it because they are only familiar with the low quality connections you find at the store. The good connectors listed in this thread won't need solder.

 

[GEN14OWNER]

In the marine side I have heard the opposite. That the solder connectors can be more likely to fail from vibrations etc and good crimps are recommened connection method. That being said I use the solder seal connectors cause I like them too

I’ve been building Public Safety Vehicles for 25 years. Police Cars, Motorcycles (Street and off road), Ambulance, AIR Ambulance, Fire Trucks, Fire Boat Rescue, etc…

Installing Motorola, Kenwood, Icom, Bendex King, GE, Federal Signal, Whelen, David Clarke, Setcom, Firecom, Sigtronics and on & on.

Police cars & Ambulance, sure… “crimp”. They won’t be in service that long and usually don’t get much of a beating (relatively speaking).

But Motorcycles.. anything with a lot of vibration like a Harley Davidson or Dirt bikes… Fire Trucks that go off road to fight wild fires. Anything airborne or boats that will be exposed to extreme elements? I ALWAYS “solder” my crimps and heat shrink, flooded with dielectric grease to keep the connections secure and waterproof when possible.

A machine does “Factory” crimps. YOU are not a “machine” and you are kidding yourself if you think “your” crimp is just as good as a factory-machined crimp.

But.. IT’S A PICKUP TRUCK!

How long are you going to keep it before you sell it or trade it in for a new one?

How important is it that your crimp doesn’t fail?

“ME”?… I solder my crimps. I don’t want to be out in the middle of nowhere where only a life flight Helicopter can reach me when a crimp rattles loose.

But that's “me”.

You do “you”.

BTW... by "YOU" I don't mean "you" personally. I don't know you. I mean it in the general sense of anyone reading this post.

 

[dolsen]

I would like to circle back on this and thank everyone for their input. I built my own wiring harness to go from the HCM to the left hand side ride height sensors. It was only 6 wires and 2 sensors, but for me this was a big job. I’m proud of the work that I did. It’s certainly nothing fancy, but I did try to replicate OEM parts and quality to the best of my (limited) abilities.

This gives me the confidence to do a lot more in the future!

Left rear ride height sensor

Left front ride height sensor wire terminals

Wiring harness running through the drivers floor board

Left front ride height sensor

 

[WD8CXB]

I would like to circle back on this and thank everyone for their input. I built my own wiring harness to go from the HCM to the left hand side ride height sensors. It was only 6 wires and 2 sensors, but for me this was a big job. I’m proud of the work that I did. It’s certainly nothing fancy, but I did try to replicate OEM parts and quality to the best of my (limited) abilities.

This gives me the confidence to do a lot more in the future!

Left rear ride height sensor

Left front ride height sensor wire terminals

Wiring harness running through the drivers floor board

Left front ride height sensor

Looks awesome! Good job!

 

[Bryan Simon]

Wiring and building harnesses is not for the timid.
It is very time consuming and if you use the proper automotive stock type connectors and terminals it can get pricey in a hurry. Not to mention the right TXL, SXL, and GXL coated wire.

Ive wired about six 60s hot rods, three of them my own. I learned something on every of these cars.
Still making changes to one of them. Added sequential fuel injection, so there are some modifications there.
AC and Fuel Injection ECM do not talk to each other and this creates cooling fans issues (solved and installing tomorrow)
Modern updated instruments also don’t play well with ECM, and the ECM needs to drive the gauges. (Temporary work arounds in the works). Fuel pump currently bypassing ECM till I get everything worked out.

Point is, it’s not hard, but requires thought, patience, and time.

good luck

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