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Upgraded fuel pump harness.
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kalispell365
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PostPosted: Thu Aug 30, 2018 12:14 pm    Post subject: Upgraded fuel pump harness. Reply with quote

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.
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shagginwagon83
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PostPosted: Thu Aug 30, 2018 12:19 pm    Post subject: Re: Upgraded fuel pump harness. Reply with quote

Damn, I love a good wiring thread Popcorn 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
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Brandon
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dhaavers
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PostPosted: Thu Aug 30, 2018 12:29 pm    Post subject: Re: Upgraded fuel pump harness. Reply with quote

x2!

Very nice work & materials...(I think you just re-defined "bombproof"...???) Shocked

Looks great! Cool Wink

- Dave
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mellowslow
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PostPosted: Thu Aug 30, 2018 12:36 pm    Post subject: Re: Upgraded fuel pump harness. Reply with quote

Hi kalispell,

Thanks for posting up.

What kind of crimp tool are you using for such a proper result?
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DanHoug
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PostPosted: Thu Aug 30, 2018 12:41 pm    Post subject: Re: Upgraded fuel pump harness. Reply with quote

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.
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shagginwagon83
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PostPosted: Thu Aug 30, 2018 12:41 pm    Post subject: Re: Upgraded fuel pump harness. Reply with quote

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.
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kalispell365
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PostPosted: Thu Aug 30, 2018 12:50 pm    Post subject: Re: Upgraded fuel pump harness. Reply with quote

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!
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Vanagon Nut
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PostPosted: Thu Aug 30, 2018 1:13 pm    Post subject: Re: Upgraded fuel pump harness. Reply with quote

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.
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shagginwagon83
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PostPosted: Fri Dec 07, 2018 6:12 am    Post subject: Re: Upgraded fuel pump harness. Reply with quote

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.

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kalispell365
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PostPosted: Fri Dec 07, 2018 1:46 pm    Post subject: Re: Upgraded fuel pump harness. Reply with quote

Brandon,
I get the bulk of my connectors from Digikey, but I dont remember where i specifically got the male terminals in the picture.
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16CVs Premium Member
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PostPosted: Fri Dec 07, 2018 7:27 pm    Post subject: Re: Upgraded fuel pump harness. Reply with quote

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
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bobhill8
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PostPosted: Mon Dec 10, 2018 4:51 pm    Post subject: Re: Upgraded fuel pump harness. Reply with quote

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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