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Andross
Samba Member
Joined: December 07, 2011
Posts: 147
Location: Robson, BC
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 Posted: Thu Feb 27, 2020 8:01 pm Post subject: Alternator Wiring Harness DIY Build with materials list |
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I recently discovered that I needed to replace my alternator wiring harness after diagnosing a no start issue.
I found lots of information on harness' for sale but no specs on materials to build your own. Since I had to do it anyway as I live in the great white north not down the street from GW here are the necessary materials.
30" 6 ga. red wire
60" 10 ga. red wire
60" 16 ga. blue wire
1@6 ga. 5/16" ring terminal
1@4 ga. 5/16" ring terminal
1@10ga. 1/4" ring terminal (I used an 8 ga, as they work great and are way beefier)
1@16ga. Male spade terminal
1@16ga. ~3/16" Ring terminal
Heat Shrink Tubing:
16"@1/2"
48"@3/8"
2"@1/4"
2x1.5"@1/8"
Other than that all you need is a GOOD set of crimpers, and a heatgun. I just pull the vinyl off of the typical red/blue/yellow crimpers so I can do a proper two step crimp. I your crimpers aren't big enough for the 4ga. terminal: crease the crimp with a steel chisel then squeeze it closed in the vise.
I added a second wire on the trigger post to feed a relay for my aux battery which is under the bed in the back of my van, just forward of the ECU. So I continued the harness through the grommet from the rear heater that I removed ages ago.
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0to60in6min
Samba Member
Joined: November 27, 2006
Posts: 3460
Location: OR & CA (Oregon/California)
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| Posted: Fri Feb 28, 2020 12:02 am Post subject: Re: Alternator Wiring Harness DIY Build with materials list |
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nice job Andrew...
it's the way to do...
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Steve M.
Samba Member
Joined: July 30, 2013
Posts: 6933
Location: Fort Lauderdale, Fl.
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| Posted: Fri Feb 28, 2020 5:57 am Post subject: Re: Alternator Wiring Harness DIY Build with materials list |
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I would strongly recommend using "Adhesive Lined" heat Shrink.
The sealant inside the heat shrink effectively waterproofs it to prevent corrosion at the wire crimp.
Alternatively you could smear silicone over the crimp before sliding the heat shrink over it and make a mess when it squeezes out!
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This free advice is worth exactly what you paid for it.
There are seven days in a week. Someday is not one of them. |
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djkeev
Samba Moderator
Joined: September 30, 2007
Posts: 32988
Location: Reading Pennsylvania
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Andross
Samba Member
Joined: December 07, 2011
Posts: 147
Location: Robson, BC
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| Posted: Fri Feb 28, 2020 8:22 am Post subject: Re: Alternator Wiring Harness DIY Build with materials list |
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Happy to give back!
Yes, should have mentioned, I used short pieces of dual wall adhesive lined heat shrink at the crimps and single wall for the looming. Then slathered dielectric grease on the connections after installed.
-Andrew |
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dhaavers
Samba Member
Joined: March 19, 2010
Posts: 8509
Location: NE MN (tinyurl.com/dhaaverslocation)
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| Posted: Fri Feb 28, 2020 10:02 am Post subject: Re: Alternator Wiring Harness DIY Build with materials list |
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Really nice work and a great post... 
- Dave
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86 White Wolfsburg Westy Weekender
"The WonderVan"
<EDITED TO PROTECT INNOCENT PIXELS> |
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0to60in6min
Samba Member
Joined: November 27, 2006
Posts: 3460
Location: OR & CA (Oregon/California)
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| Posted: Fri Feb 28, 2020 12:41 pm Post subject: Re: Alternator Wiring Harness DIY Build with materials list |
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hey Andrew...
you may want to do a whole bunch and sell them to us... the one like me because I'm lazy...
hehe
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Steve M.
Samba Member
Joined: July 30, 2013
Posts: 6933
Location: Fort Lauderdale, Fl.
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| Posted: Fri Feb 28, 2020 4:14 pm Post subject: Re: Alternator Wiring Harness DIY Build with materials list |
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| Andross wrote: |
Happy to give back!
Yes, should have mentioned, I used short pieces of dual wall adhesive lined heat shrink at the crimps and single wall for the looming. Then slathered dielectric grease on the connections after installed.
-Andrew |
👍👍👍
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This free advice is worth exactly what you paid for it.
There are seven days in a week. Someday is not one of them. |
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Andross
Samba Member
Joined: December 07, 2011
Posts: 147
Location: Robson, BC
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| Posted: Sun Mar 01, 2020 12:58 am Post subject: Re: Alternator Wiring Harness DIY Build with materials list |
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| Haha, yes if anyone is too lazy and wants to buy one send me a pm |
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