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JoeM
Samba Member
Joined: April 01, 2018
Posts: 69
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 Posted: Tue Feb 04, 2025 11:13 pm Post subject: Oh @#$%&! I just cut through my wire harness! Help! |
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Well, that was a lesson I'll remember. Repairing my rear quarter panel, I learnt that there is a wire harness that is snuck between the skin. Now that I cut through it, I've tried repairing it. Does anyone have any thoughts on if this is safe and acceptable?
Thanks,
Joe
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sputnick60
Samba Moderator
Joined: July 22, 2007
Posts: 4144
Location: In Molinya Orbit
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| Posted: Wed Feb 05, 2025 5:23 am Post subject: Re: Oh @#$%&! I just cut through my wire harness! Help! |
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Ouch!
Personally I couldn't live with that and would replace it, which is what I did on my car when work was done to my car a few years ago and the guys cut though the front loom on my car.
Your repair seems fine though. You could benefit with providing a wrap of Tesa tape to hold the bundle together and putting a sheath over the top of that. The sheath might be a little late since you've joined it already. There are split versions on the market that could work.
Don't use insulation tape. it dries up and unravels over time.
Nicholas
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kingkarmann
Samba Member
Joined: November 05, 2003
Posts: 4614
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| Posted: Wed Feb 05, 2025 9:06 am Post subject: Re: Oh @#$%&! I just cut through my wire harness! Help! |
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Much better that crimp connectors.
I would be very comfortable. Looks like a quality repair.
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runamoc 
Samba Member
Joined: June 19, 2006
Posts: 6327
Location: 37.5N 77.1W
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| Posted: Wed Feb 05, 2025 9:11 pm Post subject: Re: Oh @#$%&! I just cut through my wire harness! Help! |
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I used crimp connectors. I pushed the metal part out of the plastic tube, crimped the two wire ends, soldered the connection then put heat shrink tubing over that.
The ends of the original wires were too short to reach where they had to go on my re-wire. Wanted to keep original colors. So, I staggered the cuts in the harness and added about 18" of wire between the cuts and splices. Used spiral wrap then electrical tape over that.
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JoeM
Samba Member
Joined: April 01, 2018
Posts: 69
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| Posted: Thu Feb 06, 2025 4:00 pm Post subject: Re: Oh @#$%&! I just cut through my wire harness! Help! |
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Thanks everyone for the advice and support 
I noticed that the harness was not meant to be wedged in that low in the quarter panel, there is a lot of room above it. I managed to move the harness to that area, which puts it safely away from any welding I'll be doing.
Cheers,
Joe |
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