We would love to build you a custom harness in our shop but we understand that isn't for everyone. We still want you to succeed, so we'd like to share some of the secrets to our wiring success. Wiring is a skill just like welding is a skill. With good coaching and high quality tools anyone can build a decent harness, but becoming the best takes years of experience.
We'll start you off with a few basic principles:A good crimp is achieved with proper tools at the proper settings. Sometimes connections can be forced (improper tools or crimping a wire too tight or too loose) but their longevity and current handling come into question, even if it "looks OK". A proper crimp on a barrel type connector will have wire showing in the inspection hole with about a half wire diameter of gap to the insulation. A proper crimp on a stamped connector needs to have bare wire showing on both sides of the wings. Grommets should be used if supplied with the connector. The wings should curve down into the wire in the shape of a lowercase 'm'. All crimps should be tested with a firm tug to ensure strength.
Harness flexibility is achieved with proper planning and wire twisting. Bundles of wire should be gently hand twisted before being tied together or placed in heat shrink. Be mindful of creating stiff points. We have seen many harness failures through the use of the stiff RayChem boots and improperly secured wire. The wire always breaks right where it exits the boot.
When putting a boot over a connector the wire should be twisted in a way that pulling on the connector will not stress the wire.