Tips for harness assembly include proper cable placement, use of quality zip ties and terminals, color-coded wires, and an accurate drawing. Neatly routed wiring with zip ties is safer and more professional than tape. Quality terminals and crimping tools are important to avoid damaging wires.
Some harness assembly tips include proper cable placement, use of quality zip ties, and proper placement of straps. Other tips for quality wire harness assembly include using only color coded wires that are safety rated, quality terminals, and a quality terminal crimping tool to place the terminals on the different wires. A valuable tip when making a harness assembly is to make an accurate drawing indicating the placement of the harness, the placement of the terminals and the routing and color of the many wires.
A home mechanic or repairman will often be forced to create a harness to replace an old and unsafe unit or to connect additional components to an existing harness. There are several tips that can help you build a harness assembly and maintain safety standards along the way. One of the best tips when creating a harness assembly is to place the wires neatly and orderly to avoid tangling the wires. Well-routed wiring not only looks more professional, but it’s also less prone to electric shock and short circuits from twisted wires touching each other. You may need to build some type of mounting board out of wood and nails to wrap the wire around during assembly.
Instead of electrical tape, one tip for neat and tidy wiring is to use plastic zip ties to secure the wiring. The small plastic ties are very easy to manipulate and create a secure connection once tightened. This will eliminate wire shifting after assembly and will also allow for an unobstructed view of the wires once they are secured. Duct tape can loosen after a short time and often leaves a sticky, detached harness. An installation tool is also available to ensure all zip ties have the correct seal, and the tool also cuts the label end of the zip tie, leaving a clean installation.
Using color coded wire whenever possible to make tracing a wire easier and using a quality terminal crimping tool will result in a quality harness assembly. It’s also important to use quality terminals, the connection pieces that connect the wire to another component, when making a harness assembly. Some terminal crimping tools damage the wire because the terminal is too tight. A quality terminal connector or crimping tool will not crush the terminal onto the wire; rather it will form a round crimp and tighten it tightly around the wire.
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