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Basic Steps for Wire Harness Building – Part II

September 1, 2015

Basic Steps for Wire Harness Building – Part II

In the previous post, we had discussed the initial steps to building a harness. We began by creating a wiring diagram, collecting the tools, stripping the wires, and cutting and attaching the heat shrink. We also showcased the steps for connecting and crimping the terminal and wire, and shrinking the heat shrink. In this post, we will take a look at the remaining steps involved in building a wire harness.

Steps to Build a Wire Harness :

The following points showcase the basic requirements and steps to be taken to build a wire harness.

  • Interlacing Multiple Wires: The method shown here is just one way to splice multiple wires. Cut the insulation off the ends of the wires, and insert them into a crimp tubing. Ensure that the wires go all the way through the tubing. Pass the wires through the heat shrink tubing as well. Using a crimping tool, apply force to the crimp tubing. Then use the heat gun to shrink the heat shrink tubing.
  • Examine the Connectors: As most wire harnesses are built for demanding applications in extreme environments, it is suitable to use weather pack connectors. These are similar to factory connectors, but slightly different. These connectors consist of a male and female housing, and each housing comprises seals and terminals.
  • Sealing & Crimping the Wire: First strip about 3/8ʺ of insulation from the wire. Then slide a seal onto the wire. Using a crimping tool, crimp the wire terminal. Ensure that crimping is done only to the crimp area, and not to any other part of the terminal.
  • Attach the Terminal: Insert the wire with the seal into the terminal while it is still in the crimper. Squeeze down and make the crimp. You can also attach small metal strips to hold the rubber seal in place.
  • Attach the Wire to the Male Housing: Now the wire is ready for assembly. Insert the terminal into the male housing. Keep pushing the terminal inside till you hear a click. Once this is completed, close the housing flap. The flap will go around the wire.
  • Connect the Wire to the Female Housing and Attach the Connectors: Perform the same procedure with the female housing. You can use a zip tie to hold all the wires together. Place a large green seal on the outside of the female housing. Then slide the male housing over the female housing, and connect them together.

These are the basic steps to build a wire harness. After this, the harness can be installed into the application equipment. A bit of practice and patience can help you to create a harness of immense quality.

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