John uses Delphi Metri-pack connectors (the same as GM) for most harness connections. They are easy to assemble and crimp, and easy to connect and disconnect when complete. For bulkheads (no grommets allowed in Unfair!), he uses Molex XRC connectors. They are very similar to a mil-spec connector, but are about one-quarter the cost, use a more traditional crimp, and can be disassembled when you make a mistake. The key to using bulkhead connectors is keeping track of every single wire, and writing it all down in a table that can be referenced by wire color, connector location, and intended purpose. Amperage ratings are important to factor in as well: the XRC connectors are rated to 14g wire/13 amp current. Higher current needs will have to go through the more traditional large bulkhead connector that can carry 10g wire and 40 amps. Grouping wires together in visible locations (like under the hood) is traditionally done with wraps of wiring tape or split loom plastic tubing. Those are ugly and bulky. Instead, John uses nylon mesh held in place with shrink wrap. It makes for a tidy and flexible way to run bundles of wires together, without having to use tie wraps every 4-5 inches to keep individual wires from drooping out of the harness. As we said, this won't be about connecting the gray wire to the yellow wire. Instead, follow along as John shows off some of his techniques for building a safe, reliable, and easy to service wiring harness. Here are all the pieces in a Metri-Pack connector, including the connector bodies, strain reliefs, pin and sleeve, and silicon seals.Here are all the pieces in a Metri-Pack connector, including the connector bodies, strain Just like with the Molex connector, a proper crimp is essential. This tool crimps the wire connection and seal in one step.Just like with the Molex connector, a proper crimp is essential. This tool crimps the wire Here's a proper crimp, ready for insertion into the connector body. The wire/seal/connector are inserted into the back of the connector body until it clicks into place.The wire/seal/connector are inserted into the back of the connector body until it clicks i The strain relief is inserted last. Here's the fully-connected assembly ready for years of service, while still allowing quick and easy disconnection for car maintenance.Here's the fully-connected assembly ready for years of service, while still allowing quick Turning our attention to attaching the various boxes to the car's sheetmetal, John doesn't like sheetmetal screws: "They only work a few times before stripping out, they cause injuries or rip your clothes on the other side of the panel, and they look like crap." John uses rivet nuts instead. You can see the installation tool, the hole in the sheet metal, and the rivet nut insert (the gold cad-plated slug).Turning our attention to attaching the various boxes to the car's sheetmetal, John doesn't Installation is done with two wrenches: one to hold the body square to the metal and the other to draw the insert into place.Installation is done with two wrenches: one to hold the body square to the metal and the o Properly installed, here's how the insert looks from the back side. Now the sheetmetal has a good-looking, secure, and reliable machine thread.Properly installed, here's how the insert looks from the back side. Now the sheetmetal ha Using rivet nuts lets you use attractive and long-lasting hardware, like this stainless and Delrin screw and washer combination.Using rivet nuts lets you use attractive and long-lasting hardware, like this stainless an Grouping individual wires into harnesses is usually done with cut loom, tape, or a whole bunch of tie wraps. Here's a small four wire harness and connector with wires that need some organization.Grouping individual wires into harnesses is usually done with cut loom, tape, or a whole b John likes to use nylon mesh tubing to collect all the wires going parallel. He feels it makes for an easy way to group wires together without the lumpiness of tire wraps, or the time and expense of tape or split loom. To keep the end of mesh from fraying, a short piece of shrink-wrap tubing is used. John says, "Organizing your harness with mesh and shrink wrap takes planning. You have to put it together as you go. If you wait until you're done, all your connectors are too big to run.John likes to use nylon mesh tubing to collect all the wires going parallel. He feels it m SOURCES American Autowire 150 Heller Place #17W Bellmawr NJ 08031 856-933-0801 www.americanautowire.com II Much Fabrication Germantown MD www.iimuchfabrication.com Braille Battery 941-312-5047 941-870-3381 www.braillebattery.com Prodigy Customs Apopka FL 407-832-1752 www.prodigycustoms.com Holley Performance Products 1801 Russellville Rd P.O. Box 10360 Bowling Green KY 42102 270-782-2900 www.holley.com « | 1 | 2 | View Full Article By Jim Campisano Enjoyed this Post? Subscribe to our RSS Feed, or use your favorite social media to recommend us to friends and colleagues!