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kalispell365 Samba Member
Joined: April 01, 2010 Posts: 889 Location: PNW
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Posted: Thu Aug 30, 2018 12:14 pm Post subject: Upgraded fuel pump harness. |
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Today I rewired a Vanagon fuel pump harness and ground harness. I believe the original 16 gauge (18 on early vans) is undersized. Materials used were 14 gauge marine grade tinned wire, Mil-Spec nylon multifiliment sheathing manufactured by Techflex, 3M adhesive shrink tubing, replacement Beetle horn wire boots for the fuel pump connections stainess pan head screw and toothed washer for the ground connection and factory style open barrel connectors.
_________________ 1983 Diesel Vanagon Westfalia chassis with Subaru 2.2l |
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shagginwagon83 Samba Member
Joined: February 07, 2016 Posts: 3786 Location: VA/TN
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Posted: Thu Aug 30, 2018 12:19 pm Post subject: Re: Upgraded fuel pump harness. |
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Damn, I love a good wiring thread 10/10 OP
I just started using adhesive heatshrink and its great.
Here is the link for the mesh sleeve from facebook
https://www.ebay.com/itm/3-16-BRAIDED-NYLON-SLEEVI...2749.l2649 _________________ Brandon
"Jo Ann" - '83.5 Westfalia EJ22e w/Peloquin
Instagram @joannthevan |
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dhaavers Samba Member
Joined: March 19, 2010 Posts: 7733 Location: NE MN (tinyurl.com/dhaaverslocation)
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Posted: Thu Aug 30, 2018 12:29 pm Post subject: Re: Upgraded fuel pump harness. |
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x2!
Very nice work & materials...(I think you just re-defined "bombproof"...???)
Looks great!
- Dave _________________ 86 White Wolfsburg Westy Weekender
"The WonderVan"
<EDITED TO PROTECT INNOCENT PIXELS> |
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mellowslow Samba Member
Joined: July 31, 2009 Posts: 278 Location: Vacationland
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Posted: Thu Aug 30, 2018 12:36 pm Post subject: Re: Upgraded fuel pump harness. |
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Hi kalispell,
Thanks for posting up.
What kind of crimp tool are you using for such a proper result? _________________ '87 WBWE FAS Gen V |
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DanHoug Samba Member
Joined: December 05, 2016 Posts: 4717 Location: Bemidji, MN
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Posted: Thu Aug 30, 2018 12:41 pm Post subject: Re: Upgraded fuel pump harness. |
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yeah, that was a nice open barrel crimp. Brand name and model number, please! i bought 3 off Amazon, sequentially, and finally found one i liked. can't remember the model right now but they are very handy to have around VWs for re-stuffing connector shells with new contacts. _________________ -dan
60% of what you find on the internet is wrong, including this post.
'87 Westy & '89 Westy both 2.1 4spd
Past projects can be found at--
www.thefixitworkshop.com |
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shagginwagon83 Samba Member
Joined: February 07, 2016 Posts: 3786 Location: VA/TN
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Posted: Thu Aug 30, 2018 12:41 pm Post subject: Re: Upgraded fuel pump harness. |
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I think its a ratcheting open barrel crimper. I, along with a bunch of others on The Samba, use the IWISS crimper with multiple die. Open barrel connectors are game changer.
OP can you link where you found the male connector? I'm wanting to improve the quality of my connectors. _________________ Brandon
"Jo Ann" - '83.5 Westfalia EJ22e w/Peloquin
Instagram @joannthevan |
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kalispell365 Samba Member
Joined: April 01, 2010 Posts: 889 Location: PNW
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Posted: Thu Aug 30, 2018 12:50 pm Post subject: Re: Upgraded fuel pump harness. |
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I specifically used a common, affordable crimper in these photos so others could achieve this at home, mine is Mac tools, but is identical to this:
https://www.ebay.com/itm/S-G-Tool-Aid-18600-Open-B...SwKwVaZ7~l
The advantage of this style over some of my other ratcheting crimpers is you can choose both the wire crimp size and the insulation crimp seperately, which works good when you are doing Japanese wire for example. It uses a much thinner insulation and the ratchet crimper wont perform the insulation crimp correctly.
THANK YOU all for the kind words! _________________ 1983 Diesel Vanagon Westfalia chassis with Subaru 2.2l |
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Vanagon Nut Samba Member
Joined: February 08, 2008 Posts: 10347 Location: Sunshine Coast B.C.
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Posted: Thu Aug 30, 2018 1:13 pm Post subject: Re: Upgraded fuel pump harness. |
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kalispell365 wrote: |
....replacement Beetle horn wire boots for the fuel pump connections
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Great tips! Especially that needle nose trick. Thanks.
Neil. _________________ 1981 Westy DIY 15º ABA
1988 West DIY 50º ABA
VE7TBN |
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shagginwagon83 Samba Member
Joined: February 07, 2016 Posts: 3786 Location: VA/TN
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Posted: Fri Dec 07, 2018 6:12 am Post subject: Re: Upgraded fuel pump harness. |
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What quality/grade connectors do you use? I'm looking to get some quality open barrel connectors just like this - and the open barrel you used too.
_________________ Brandon
"Jo Ann" - '83.5 Westfalia EJ22e w/Peloquin
Instagram @joannthevan |
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kalispell365 Samba Member
Joined: April 01, 2010 Posts: 889 Location: PNW
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Posted: Fri Dec 07, 2018 1:46 pm Post subject: Re: Upgraded fuel pump harness. |
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Brandon,
I get the bulk of my connectors from Digikey, but I dont remember where i specifically got the male terminals in the picture. _________________ 1983 Diesel Vanagon Westfalia chassis with Subaru 2.2l |
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16CVs Samba Member
Joined: February 22, 2004 Posts: 4020 Location: Redwood City, California
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Posted: Fri Dec 07, 2018 7:27 pm Post subject: Re: Upgraded fuel pump harness. |
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One of our own "[email protected] " Jay has all you need. On top of that he is a great guy and ships promptly.
Buy from Jay and be happy, I have always been and I have bought $100.00 of dolars of connectors from him through the years.
Stacy _________________ 1987 Syncro Westfalia Triple knob (bastard)
1989 Syncro Tristar Triple knob "Swedish"
2013 Jetta Hybrid a true "Zwitter"
Samba member # 14980
Call anytime number 650 722 4914 .
Keep Your van running and upkept tastefully for the love of the hobby.
Don't let your van end up in an "abortions" thread. |
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bobhill8 Samba Member
Joined: June 09, 2017 Posts: 734 Location: MA
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Posted: Mon Dec 10, 2018 4:51 pm Post subject: Re: Upgraded fuel pump harness. |
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X2 on Jay - good quality and easy to install. Also, thanks to the OP for this topic. Motivated me to deal with mine, which I did this weekend and found some dodgy wiring in the process. Nice to have one thing crossed off the list - working outside in December in the Northeast is not fun. |
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