- Hey team, it's Andre from High Performance
Academy, welcome along to another one of our webinars and in this webinar we will be diving
into the world of electrical connectors. Specifically we're going to be talking about
the variation available in different styles, designs, price points and what you need to
know when you're deciding on connectors to suit your next wiring harness build. Now these aren't all created equal and
specifically as I mentioned, there is a huge range between price p
oints on the likes
of an OE connector and the top shelf, maybe an autosport, milspec style connector
and not all of these are necessary for every particular application so choosing the right one
for your job is really important, it's going to ensure that first of all, you're getting the right
results, secondly, you're getting the results that suit the application. So what would suit your modified road car
or club level race car, probably isn't going to cut it at the likes of professional level
m
otorsport and vice versa for that matter. And we're also going to make sure you have a
good understanding of what's what and what you need to keep in mind there. It's also important, before we jump into this
to mention that at the end of the lesson, we will be having some questions and answers
so if you've got anything that you want me to cover off here, please ask those in the questions
and we'll get into those at the end. Alright so the first element here is what are
these connectors for and
what is our main consideration, and obviously we're looking at
a way of electrically connecting our harness to a sensor, an actuator or another part of
the harness. Now if we just jump to our overhead camera
for a moment, if I can try not to clear off the entire workbench here. We've got one of our test harnesses here
which is a professional level motorsport wiring harness, this was actually part of
our pro level wiring course that Zac built. And even here we an see there's a bit of
variation i
n this. Now this harness is built using concentric
twisting, it's sheathed in DR25, here we can see the typical Raychem heat moulded boot
used for transitions, that's all potted to make sure that it is 100% environmentally sealed. Now we've got 2 break out connectors here,
these are interface connectors for, in this case, if I turn this around, this one is for ignition
system and this one here is for our fuel injectors. So these are autosport connectors and they
come at a price point however the
y are of course very reliable. But that's not to say that's the only option,
on this particular harness we've got couple of other examples here. We've got a Deutsch DTM connector as
well, still sealed, this time not with a heat moulded boot but with a section of SCL
heat shrink. But still a perfectly acceptable solution, we'll
talk more about that as we go through. And then we've got, for a sensor that is
pretty common, uses a Bosch junior timer connector, we've got that particular
connector h
ere. There's a variety of ways of sealing these
connectors. In this case, Zac has used a section of SCL
here, these are a little bit difficult to work with at a professional harness level. And there's a variety of other connectors as
well, I'll just show one more here which in this case is another one of our DTM connectors,
this one for a knock sensor, and this is a 2 pin, this time also sealed with SCL. So that's an example of a pro level harness that
is essentially fully sealed and yeah we are
using a variety of different connector bodies
on it. Before we get too far down the line though,
I want to talk about some of the considerations that you need to be keeping in the back of
your mind when it comes to choosing connectors. First of all, this comes down to what it's going
to be for. Now when you are choosing a connector for a
particular sensor, or for that matter an actuator, you're going to be relatively limited, you're going
to obviously have to use the mating connector for that
particular product. So that might, for example be, if we get to our
overhead camera, this is a relatively cheap pressure sensor, being that it's brass bodied
but these are available from a range of manufacturers and they use a fairly
generic 3 terminal connector which we can see on the top of that. So obviously if we want to connect to that,
we do need to use the mating connector. The same would go for an ignition coil,
or maybe for a fuel injector. Now on top of that, we also need to consider
if we are connecting the harness to another part of the harness. If we're going to be doing that, that gives
us a lot more flexibility because we can essentially use any connector that suits
our purposes, as long as obviously it can take the gauge of wire that we're using as
well as the current requirements and as long as it's environmentally sealed as
required for the particular application. So what I'm getting at here is there's a
bit of variation in what we can choose depending on what we'r
e actually connecting
too. Sensors, actuators, we're pretty much limited
and then we've got flexibility when it comes to the other parts of the harness that we're
defining. The other element here to consider is what
is the application? I've already alluded to this but we've got a
wide range of applications that we might be building a harness for. This might be for a modified road car,
maybe we're just adding a small break out harness to add some extra injectors to an
existing engine. Maybe we
've done an engine swap or something
of that nature and we're just wiring up the factory ECU. That level for a road car is not particular
demanding, it's not going to be put under a huge amount of stress and strain like we'd
see in a race application. And also the results, if we suffer a failure
are probably not going to be quite as dramatic. Obviously no one wants to be stuck on
the side of the road but it's one thing being stuck on the side of the road and calling a
tow truck, it's another t
hing not finishing a race, losing out on points and wasting a
huge amount of time and money at a major race event so these are the things we need
to factor in. For a modified road car, we go to maybe
club level race car. I find that there's a lot of interchangeability
here. At the club level, essentially normally what
we do for a modified road car will, in most instances, be absolutely adequate for a
club level racecar as well. At the professional level though, that's not
the same. At a profes
sional level, we might be dealing
with cars in the $500,000 and above vicinity and this comes down to what I was saying
before, what I was mentioning before, the sort of ramifications of having a DNF sort of
step up a lot. It might cost $100,000 for a weekend of
competition when you take into account the running costs of the car, what the crew are
getting paid, accommodation and all of the other ancillaries that go around a race
meeting so having a DNF due to a wiring reliability fault really
is not acceptable when
there is that much money on the line. So those are the things we need to factory in
and obviously there's a range in there. Ultimately, particularly if it's your car, it's
really going to be your decision as to where you sit in terms of your failure tolerance and
what your budget is because the budget and failure tolerance is really going to drive a
lot of these decisions as we go. We also need to consider some of the problems
that we see with factory connectors. And the
se are often overlooked. Most people would think that factory
connectors are absolutely reliable and I can assure you that they definitely are not. While they might be absolutely fine for a
stock application on a road car, when we start modifying these cars, particularly into
serious race cars, often the level of vibration and shock loading that the cars are subjected
to, causes some problems which we'll get into in a moment. Before we get into that though, one of the
biggest factors that we n
eed to consider is simply availability of the connector bodies
and the terminals and this sort of goes without saying but if we can't buy the connector bodies
and terminals, then it's going to be very very difficult to actually build a harness using these. So this, you'd think that in this day and age it's
going to be very easy to source connectors for most engines but, well most manufacturers but
it actually is not. Some very very easy, some almost impossible. One of the ones that I've found v
ery very
difficult to find is for Ford engines, particularly late model Ford engines, it's been very
difficult for me to find brand new connector bodies and terminals for those. On the other hand, there's some where it's
very very easy. GM, Toyota, Honda, Nissan for example,
it's generally pretty easy to find those connector bodies. Now I'm just going to find this website that
I wanted to show you, which I foolishly did not bring up before I got started so bear with
me here. So this was, if w
e jump across to my laptop
screen, this was a website that, or a company I should say that were displaying at SEMA that
I bumped into and I found them quite interesting because one of the common
questions we get is where should I find X, Y, Z connector and we get people sending
us in photos of connector bodies and I mean it's impossible, we're not a wiring supplier
and ultimately our experience across the full spectrum of cars out there is absolutely
minuscule so that's very difficult for us t
o answer. But this company here, connectorexperts.com,
they seem to do a really really good job of providing connector bodies for a huge range of
different manufacturers, so you can search by make or by vehicle, you can also send them
in a photo for some of those more obscure connectors so if you are getting stuck, can't
guarantee that these guys will be able to help you but it's certainly worth a crack. Other sources that we quite often use are
Rywire in the US, Ryan is really really good with
Honda, obviously that's his specialty but
he's also got OE connectors for a fairly wide range of vehicles so definitely worthwhile
trying him out. And there are also a range of other common
wiring suppliers online that will also offer OE connector bodies. One thing I do need to mention here in the
line of buying OE connector bodies is these days, understandably there are a lot of knock
off products coming out of China and the likes. And this is a bit of a tricky one because I can't
say outright
that Chinese aftermarket connectors are all complete garbage, obviously that's not
something that you can make a blanket statement about but in general I have seen some pretty
questionable connectors coming out of Chinese suppliers so wherever possible, try and find
genuine OE connectors. That's going to guarantee you the best possible
chance. Alright so moving onto reliability. So this is something that again is easy to take
for granted with a factory connector clearly, it's designed for the f
actory engine, the factory
sensor or actuator so it should be reliable right? Well not always, one of the problems with an
OE connector, which most people would give absolutely no consideration to, is they're
usually rated at a very limited number of engagement cycles. And by engagement cycles I'm simply talking
about exactly what it sounds like, the number of times that that connector can be reliably
inserted and removed from its mating housing, sensor, actuator or whatever it
may be. Now so
me of these connectors are only
rated for a handful, maybe a dozen or 20 insertions and removals. Which on face value is probably absolutely
fine for that OE application. We don't tend to be removing the engine out
of a factory car every sort of 6-12 months, it'll probably stay there for most of its life
and probably the most likely scenario is an ignition coil or something like that being
removed so that a spark plug can be changed at 100,000 mile service. So generally the factory connectors ge
t installed
and they stay there, hence the low engagement cycles they're rated at is absolutely fine. But in our instance, we tend to be working on
our cars a lot more so the engagement cycles can be problematic and when we exceed the
engagement cycles, there's a couple of possible problems we can end up with. First of all, the actual connector may no longer
stay engaged positively. So this one here which we're going to look at
in a bit more detail, when I insert it, we can physically hear it c
lick into place, no amount
of force, within reason is going to actually be able to extract that connector from its housing
without me physically pushing down on that little clip, which is exactly what we want. So if we over engage the connector body,
exceed the cycle limit, then it may lose that spring tension and it may actually not
engage properly. The other one that's a little bit more
subtle and a little bit harder for us to notice is we may no longer have the retention
on the actual ter
minal or pin that it had originally so we can end up with a sub par
electrical connection. That one, as I say, can be a little bit
harder to notice and that can also be exacerbated by vibration which we'll get
to next. So aftermarket connectors, generally come of
course with a higher level of engagement cycles that they're rated to because they know that we're
going to be working on these cars more often. Now another, or a factory actuator that I know
to be problematic and have had personal expe
rience with is this Toyota coil. I've kind of got the solution here, which we'll
talk about in a bit more detail but we'll get this under our overhead here. So this is a Toyota coil that is relatively common,
it's used on a pretty wide range of Toyota engines, there are a few guises of this coil, that one is
actually off a Toyota 3UZ-FE. But we had these installed on our 1ZZ-FE which
is a 1.8 litre 4 cylinder naturally aspirated engine which was on our remote practice dyno. And after about 6 or
so months of use, we were
having problems with intermittent ignition misfires and it happened at certain RPM
ranges throughout the rev range which is where we were getting resonant frequencies. And essentially what it was was the tension
on the pins was insufficient, that vibration would actually allow the electrical connection to be
interrupted and that would cause the misfire. So this is actually a reasonably widely
understood problem with the Toyota coils. Here in New Zealand there is a sin
gle seat
racing series called the Toyota Racing Series, it's actually used as a feeder series to Formula 1
believe it or not. We've had the likes of Lando Norris come through,
obviously currently driving for McLaren in F1. He actually won the Toyota Racing Series back
a number of years ago so it's a valid stepping stone to F1 and, getting a little bit off track,
provides super license points as well which is relatively rare. Anyway these cars, while they have gone
through a few modifications lat
ely, the original variant used an engine that ran
this particular coil, they had exactly the same problems with it. So just the factory connector was not reliable
enough, we'll get that connector under our overhead, this is one of the connectors and
this is a factory genuine connector, comes with the little terminals and also the little seals
there as well. Interestingly, to get us through on the engine
dyno, we could actually fix that by extracting the terminals from the connector body
and es
sentially crimping them down to provide a little bit more tension on the
pin that they mate in. So that was, when we were diagnosing that
problem, we could actually kind of prove the issue and actually resolve it. Of course that's not the desired result
and it wouldn't be a permanent fix but it did get us through until we went to the
solution that we just saw which I'll talk about a little bit more. The other element there is weather tightness
of these factory connectors. Again, I've just put
it out of sight but let's
just bring that back in, we do generally find that most factory connectors will
end up a little seal, little bit like this, try and get this a little bit more central
so we can see, little rubber seal that goes over the wire, over the insulation and then
when the terminal is inserted, that will go into the back of the connector body, I'm doing
a really shoddy job of that but it goes in there and basically provides some sealing from
weather, from moisture and dirt ingr
ess. On the other side, if we turn it around,
it's a little bit difficult to see, there is actually a rubber seal at the back of this
connector as well and that will seal onto the outside of the ignition coil so most
factory connector bodies work in a similar kind of way. So they're OK to a point, they're fit for purpose
and obviously provide some level of moisture and dust ingress, I don't have an ingress protection
rating, IP rating for them, and they almost certainly will vary from one connec
tor to
another. What it does for us is when we are building a
fully sealed harness though, like the one we looked at before, it really doesn't give us
too much potential to properly boot the connector and retain that fully sealed harness. So we're going to end up at some point
basically with the wire exposed, or at least the insulation around the wire exposed and
running into the back of that connector body. Now there are some, let's just go back to our
overhead. This one here, our ignition c
oil would be very
very difficult to modify in any safe and reliable means to add a boot to the back of. I've got another one here, this is a factory
connector body for a Toyota, I think this one here might be a CAN position sensor or a
VVT actuator, there's a bit of interchangeability around but again very difficult to modify
this in any way where we could add a boot. On the other hand, this is a connector for a
Bosch EV14 style injector. There's a couple of different variants of these
on the
market but I have seen in the past, people essentially slice through the back of the
connector body and thereby giving enough room to actually apply a boot. This little section here on the side, which might
be a little bit hard to see, it's actually designed so that you can get your finger on it and
actually pull this off the injector but that actually also acts as a bit of an anchor for the
boot so that the boot doesn't come off. So sometimes it's possible to make subtle
modifications to an e
xisting connector and get a heat moulded boot onto that connector
and retain fully sealed harness but that would be the exception rather than the norm. On top of weather tightness, the other issue that
do have to consider is heat damage. This normally becomes more of an issue if we're
dealing with a vehicle that's quite old. A classic example of this is the Nissan RB,
SR actually is the same problem where the wiring harness for the ignition coil sits down
in the valley between the two camshafts
and basically it's got a cover in stock form that runs
over the top of that and it sits in there, basically like an oven so after the engine is
15 or 20 years old and done 100,000 plus miles, you'll often find that when you go to extract
one of these connector bodies, when you actually depress the little tabs so you can
extract it, it'll simply break off, the plastic's gone hard and brittle, it's not going to
handle heat. Now considerations here is getting airflow
to the areas that are going t
o get hot anyway. Obviously if we get too much heat into any
connector it's not going to last. Harness routing, keeping it away from exhaust
systems, turbochargers, wastegates, also is always advisable, irrespective of what style
of harness we are building. Alright so let's talk about the solution to the
problem where we've got an actuator or a sensor that is either unreliable, case in point
here is our Toyota ignition coil, but we could use this for any sensor or actuator where
maybe we ca
n't source the connector body, the connector body is known to be problematic
like the Toyota ignition coil, or we want to build a fully sealed harness and we want to terminate
to an autosport connector. So the idea here is what we're going to do is
take that factory sensor or actuator and we're going to pot it so that we can then terminate
it to whatever connector we choose. So as I said, we've already seen this but let's
have a little bit more of a detailed look at it, we'll get that back under
our overhead. So this one actually hasn't been completed
yet, this is sort of part way through the process. But essentially what we do here is actually
solder the conductors onto the terminals or pins inside the connector itself, to the actuator
and then we pot the back of that connector using a potting compound. Now for anyone who's followed us for a fair
while, you'll know that we are reasonably vocal in our dislike for solder. And I still stand by that but it is very
difficult in our indust
ry to make blanket rules and for every rule of course there is
an exception. Now getting onto this, we need to understand
the problems that exist with solder and if we understand the problems with solder then we
can understand some of the ways that we can work around that and prevent these problems
actually causing a failure of our wiring harness. So the biggest one is that solder will tend to
wick up the conductor. This gets worse when we're applying too much
heat and too much solder and it wil
l wick a long way up the wire and the problem is not
actually the solder joint itself, it's the point where the solder stops and the wire conductors
continue and that basically becomes a potential failure point and I'll be clear, it's not going to
say that it will fail but it is a potential failure point if the wire is then subjected to vibration
or movement. Basically it can harden at that point and the wire
conductors can break. So with this, just coming back to our overhead
here, all of our s
oldering is done inside the back of this connector body. Being very careful as well that we're not
applying excessive heat or an excessive amount of solder so the wicking effect is all retained
essentially inside the connector body. And then because we are filling this with a
resin, a 2 pot epoxy, this provides mechanical strain relief, essentially locking the solder joint
in position, it can't move, it can't vibrate so the failure mode is essentially eliminated. To do that, there's a couple of
different options
on the market. We'll get under our overhead here, this one is
the Hellermann V9500 2 pot epoxy. The other one that's probably just about
more common is the ResinTech RT125 and we use that for potting actuators and sensors
like that. We also use it for sealing our harnesses
and gluing down our heat moulded boots as well so something that we will have on
hand if we are doing any motorsport wiring. Obviously that requires a bit of time to
allow it to set up, generally I like t
o allow them about 24 hours to set completely and
I probably should have mentioned as well, before we do that, the wiring that's going to
this is already sheathed in DR25 which is kind of our industry standard. So this then gives us a flying lead, this one
probably a little bit excessively long for what it is but essentially gives us a flying lead that
we can then terminate as I mentioned to our choice of connector body. Be that something high end like an autosport
connector or be that somethin
g a little bit more entry level like the Deutsch DTM connectors
that we'll talk about in a moment. Generally when we're working at this level,
we would be using Tefzel wire as well. Benefits with Tefzel, there are a few of them,
one of the biggest ones though is that the insulation around the Tefzel wire is
extremely thin compared to TXL wire just for an example. The outside diameter of the wire for the same
gauge is generally around about half or thereabouts. So that's some options there tha
t are available. Once that's done, I did mention we are going
to add a heat moulded boot. So this is the sort of heat moulded boot that
we can find, these are available in just about an unlimited range of sizes and shapes and
what we do there is simply install that over the end of our wire and get that into location,
doesn't look like it's a particularly good fit at the moment but these have a massive shrink
ratio, so this would be shrunk down. Before it's shrunk completely as well, it is also
s
ealed at both ends with a line of that epoxy that we just looked at and that goes one step
further, as well as the epoxy that we've potted the connector with, when those heat moulded
boots are recovered, they become semi rigid so that again adds further strain relief to
the finished part. Now there's an obvious and significant
downside to this in that if we're going to this trouble, no longer do we have the
flexibility of popping into the OE manufacturer's supplier and buying a new ignition c
oil or
sensor or whatever it is that we've potted. So that is something we do need to consider. Generally with this sort of harness construction
technique, we'd go ahead and prepare spares for any of the common sensors or actuators
and have those at the track with us so if we have an ignition coil fail, it gets to be a slightly
more serious operation to replace that coil, we do need a prepared spare ahead of time. Alright so this brings us to the obvious question
of what connectors should we b
e using? And we've talked about factory connectors and
why at anything beyond road car or lightly modified road car, club level race car, factory
connectors are often going to give you problems. What are our options to go beyond that? So I mean at the high end, we of course
can look at an autosport connector like this one, I'll get that under our overhead. I'm not going to go into too much detail on
these, we've got a number of webinars in the archive, you can check on if you want to know
more
about how to work with these or how to choose them but I think probably anyone
watching this webinar, it's unlikely that that's your first time seeing an autosport connector. On the outside, the autosport connector is a
incredibly reliable connector. It does an insane job at what it's designed for
but it does come with some significant downsides as well. Number one of those of course is the cost. It's not unusual for a pair, connector body pair
like this to be somewhere in the $200-$300 USD rang
e. On top of that, you also need some pretty expensive
tooling to be able to work with that. The GMC crimp tool and positioners to work with
all of the contacts that go along with that. A little bit of specialised knowledge in terms of
how to actually work with them but honestly it's not rocket science. Again we've got webinars that cover exactly
how to do this, ensure that you are getting the best results and working reliably. On top of this, another advantage with the
autosport connectors is
they do come in a range of different keyways. What I mean by this is the coloured band, if we
go back to our overhead here, on this one we can see it's got a red coloured band. And that refers to the keyway, it's going to be
difficult to see, we do have little keys here in the shell, the outside of the body, which
mate with the mating connector. So essentially red to red, is going to go
together. Now this might seem irrelevant but in some
instances, particularly when we're looking at the smal
ler autosport connectors, and we'll
get our pro harness back into shot here. In this instance we've got two connector bodies
that are absolutely identical in every way shape form, one for our fuel and one for our ignition. And these are going to essentially be located
right beside each other in the engine bay when everything's installed. So obviously, in that instance, it would be
very easy to accidentally connect the mating harness to the wrong side. So that's why this one is a yellow keyway
an
d this one is a red keyway. The mating connectors, the keying is different,
meaning that they will only go onto the colour coded side. So it's impossible to incorrectly connect them. So again you might be thinking it's not too
relevant and in most instances there's going to be some separation between your connectors
but when we're working particularly with the likes of the autosport line, or ASL connectors which are
quite common and can be used in a range of different flying lead applications l
ike our coil
that we just saw, we can end up with a lot of these in very close proximity so using the
different coloured keyways is really really important to avoid accidents or incorrect
insertions. All of these autosport connectors as well are
designed to work with the Raychem or Hellermann heat moulded boots and again, I'll get it back
into shot, let's actually try another one here, just to demonstrate the sort of range of these
that are available. This is a connector that's designed to have
2
heavy gauge contacts for power distribution and then 3 smaller contacts that are designed for
lower current draw, so these are all in the same body. So what we can see on the back of this is this
gnurling here along with this little machined lip. So that lip is designed to take the matching
lip on a heat moulded boot and between that, the epoxy that we use and that gnurling,
means that it's going to be positively located and it's not going to come off. So great product but expensive and requir
es
a little bit of knowledge to work with. Let's move to our cheaper entry level which is
probably my go to, which is the Deutsch range of DT, DTM and DTP connectors. So these are provided in 3 different families
I guess you'd call them, depending on our current requirements. We've already seen them, let's just get a
couple of these into our overhead shot here. So here I've got a 3 way and a 4 way, let's
actually mate them around the right way. So these work with some pretty common
easy to sourc
e and relatively well priced contacts. We've got a male pin and a female socket. And then they also require these little wedge
locks as well which go in after the terminals have been inserted to prevent them coming out. So the upside of these is that they are really
reliable for the price point. The other upside is that price point, a 2 or
3 way connector body, depending where you're getting them from and what currency
you're in, probably somewhere in the region of about $10 USD so absolutely no
t going to
break the bank. Another really nice feature with these is you
don't need any expensive tooling to work with them. There are some generic crimp tools like
this one here. Get this under our overhead. This is designed to work with the likes of the
DT connectors. This one is for 14, 16 and 18 gauge for a size
16 contact. I've got another one over here as well, this is
for a size 12 contact. And I don't think I have my size 20 contact one
but essentially they all look the same. It's been
a while since I bought one of these
but I think they're around about maybe $40 odd USD, thereabouts so again certainly
not going to break the bank. They don't require any specialist knowledge
in order to use them so that is one of the reason why we use a lot of those DTM
connector. In terms of their specification as well, they are
rated at 100 engagement cycles minimum. So that's not to say they're going to fall to
pieces at 100 engagement cycles but they are tested to ensure that they don't
degrade or lose any of their retention or electrical conductivity at 100 engagement
cycles and even in a motorsport application, 100 engagement cycles is quite a lot. Also rated to work reliably between -55°C
and 125°C which is probably more than sufficient for just about any application we
would need. Beyond that, you're probably going to have
other problems with your actual wire deteriorating and failing as well. Also rated for high levels of shock and
vibration immunity which is again, as I
related to, something that a lot of the OE
connector bodies are not. So again, they're really designed with our
motorsport environment in mind. The rating for their moisture and dirt ingress
protection is an IP68 which is pretty meaningless to most people but essentially, that IP rating
means that they are reliable if they're fully submerged under water up to 1.5 metres for
30 minutes I think, don't quote me on that but there or thereabouts. Essentially I wouldn't probably expect that
they're
going to be a great solution to fit on the outside of a submarine but for most
instances in a motorsport application they're going to be more than sufficient. You can use them on offroad vehicles, you
can power wash them and they're going to retain reliability as long as they are used
properly. Actually, I'll come back as well for a moment
and talk about the seals, let's go to our overhead, on these factory connectors. This is something I didn't mention at the time. One of the problems with the
se seals is that
they are designed for automotive grade wiring that the OEs used, so TXL for example with
quite a large thickness of insulation. So if you're using TXL wire in 20 gauge,
you're going to have a good amount of grip with that seal on the insulation. However for our uses in a motorsport application,
it's not uncommon for us to be using 22 or even 24 gauge wire and if we're using tefzel
wire, not only is the conductor smaller but the insulation is also much thinner. We can get to a s
ituation where those factory
seals are no longer going to actually provide any grip or bite on our insulation so what
this means is that essentially everything looks fine but there is a moisture path directly
through the back of the seal so on the other hand the DTM or the Deutsch family of
connectors are designed exactly for this use on tefzel wire. So moving on, there are 3 ranges of these and
this really comes down to the current handling capability that you need. The two that I've got these
are both in the
DTM range and this would suit most of our wiring that we're going to be doing in and
around the engine where our current handling capability isn't really a huge concern. The DTM will work with up to 22 gauge wire and
a size 20 contact. It's rated by Deutsch at 7.5 amps maximum
so again you're probably not going to be exceeding that on most of your sensors or
actuators on the engine. On the other hand though if you do want
to run maybe a fuel pump or a radiator fan, that's prob
ably going to be below what you're
going to need in terms of current handling capability. So we've got options there, before we go onto that,
the DTM family, they're available in 2 position, 3 position, 4 position, 6, 8 and 12 position. So a fairly wide range of options there to
suit just about anything that you need to wire up. So current handling capability, if DTM's not
going to cut it, if you need to go above 7.5 amps, then you can step up to the DT family. I don't unfortunately have the DT
and DTP here
in front of me but essentially they look all but identical, they're just physically larger with
larger contacts that are going to go into them. The DT uses a size 16 contact and is rated at
13 amps. It'll work with 14 through to 20 gauge wire and
those again available in the same 2, 3, 4, 6, 8 and 12 position. Then if 13 amps is still not enough, if you
really want to pull some serious current, you can go to the DTP connector. Again, very similar, just a bigger step up in
size agai
n. These use size 12 contacts rated 25 amps,
10 to 14 gauge wire. These are only available in 2 and 4 position. So it's a pretty wide range of family of
connectors there that is going to cover most of your applications. They are easy to work with, they work well,
they're cost effective, but of course they do have some downsides. One of these is that in a complex wiring
harness, you can end up with a lot of these. There are no keyway options for them which
means that if you've got connectors ne
arby, it can be very easy to inadvertently connect
the wrong connector up so that's one thing you need to be mindful of. You do need to watch out for that, which is
why, it's really important to go to the trouble of properly labelling your wiring. So this one here has EOT which stands for
engine oil temperature. This one here is our gearbox interface for
our gearbox wiring. So it's easy if we're taking our time and we're
careful. But in the heat of the moment in a pitstop
where something's gone
wrong and we're rushing to get the car back out onto the
track, particularly if we've got someone else working on the car that maybe doesn't
know it inside and out like the person who built the wiring harness, that's when things
can go wrong and a lack of keyway options is problematic. The other aspect which sounds maybe a little
bit silly is that these actually end up quite bulky when we've got a lot of them in close
proximity so it really tends to end up adding a lot of unnecessary bulk to th
e
harness so that's something to watch. Actually one element I haven't talked about
here as well with these is the ability to add boots to these and you do need to be
careful, if you are buying these connectors, I don't have a non booted variant but this
side of the connector which takes the female socket, this actually has a modification
which is this extended section of the housing here, it has this little recess here which is designed
to take a heat moulded boot. And you've got options ther
e, as we saw with
that harness I've shown you as a sample, it's quite common to actually just use a section
of SCL, semi rigid heat shrink as the boot. Mainly just as a cost saving but as long as
you're a little bit careful with the application of heat, there's absolutely no reason why you
cannot use a Hellermann or, Raychem boot on one of these as well, there's a range that
do fit them. The opposite side of those connectors which
I'll just bring into shot, these do not take boots so you're st
ill not going to have a
completely sealed harness, albeit these ones would generally be located on the
sensor or actuator side anyway. Alright getting on towards the end of this
so again just another reminder if you've got questions, please ask them and we'll get
into those in a second. I don't have this one here to show you
at the moment but another option very similar to the DTM range of connectors
but much much smaller, much more compact and much much more expensive is the TE
Connectivity a
utosport composite range. So jump across to my laptop screen, this is
the autosport composite, as its name implies it's a thermo plastic composite housing and
uses conventional autosport style contacts and it's tiny, it's probably for its size, it's a 6
position connector, if we had this side by side with a DTM 6 way, it's probably about a quarter
of the size so it's very very small, way smaller than the 3 pin that I had to show you on
that overhead. So benefit there of course is, gets around th
e
problem with bulk. These are also designed purely for motorsport
use so they are designed to take boots on both sides. These were actually designed from what I understand,
we actually toured TE Connectivity's facility in the UK back in 2019 and they designed these in conjunction
with Williams for their F1 car. I haven't seen too many of them out in the wild
but they are starting to become a little bit more popular, probably a thing that is holding them
back is the insane price tag. Here in N
ew Zealand, I think I paid about $110 NZD
so about $70 or so USD for a matching pair, maybe $80 USD for a matching pair so it's quite
a high price point, particularly if you need multiples of these. As I mentioned, they are available with multiple
keyways though so gets us around that problem of interconnectivity when you've got a lot that
are located in the same place. These can also be stacked in close proximity,
they've got a slot down the side of them so you can actually stack multiple conne
ctors
side by side and they are also designed for reliability to actually take a cable tie, so you
can see here there's a little slot through the housing, once it's connected you can put
a cable tie through that, you can use that cable tie to secure it to part of the
engine or chassis or a mounting tab but when that cable tie is also installed, it
ensures that the two halves of the connector cannot come apart. Downsides in terms of working with these,
other than the cost, you're also back to r
equiring the DMC crimp tool and positioner
to work with them so definitely they're not going to be for everyone but they are a nice
solution nonetheless, good to know that they do exist. Actually in terms of size, we can see the sizes
dimension, I think that's 12.8 mm and 14 mm high so yeah, pretty damn small. Last one we're going to talk about today, and
again unfortunately I don't have a sample to show you, is a generic milspec connector. And this term, I really don't like using it because
it
is thrown around so much with a lack of understanding of what that term actually
means and it is of course just a military specification which a lot of these connectors
are made to a military specification, just a way of ensuring that they will perform
in a certain way under certain conditions. But yeah as I say that term's sort of thrown
around so much and with not a lot of understanding. So jump across to my laptop screen again,
this is actually a pair of these milspec connectors that we use
d on one of our Toyota
86s, we actually had a reliability problem, talking about connectors, that was quite
interesting and again I should have taken another shot that shows a bit of the location
of this but these two connectors are the main wiring harness between the engine and the
chassis and in stock form it uses a really large oval shaped plastic housing that includes
terminals of 2 different gauges. And despite that never being modified,
we actually had problems consistently with the reli
ability of that factory connector,
we put it down to the fact that with our turbo installation, it's probably a lot more heat
than in stock form and it sort of tends to funnel up the back of the engine bay from the front pipe
and basically come up underneath the connector but we were having problems with
reliability of that VVT connection through that factory connector. In the end after 3 or 4 problems, we threw that
away and we replaced it with this pair of these milspec connectors. Now these
are available from a range of different
suppliers. They are very similar to an autosport connector but
they have some very important differences. The first of all being the price point. They're probably about a third to a half of the
cost of a comparable autosport connector. No need to use expensive specialised crimp
tooling as well, easy to work with these with conventional crimp tooling. The other thing that's really important is that
we could not have actually used an autosport connector in
this application due to, and it's very
hard to see, the fact that we are dealing with factory wiring here which has that very thick
insulation which I've already sort of mentioned. Now that will simply not go through the
autosport connector. If we actually get this one under our overhead,
this is designed for 20 gauge wire or size 20 contacts with 20 gauge wire and the size of the
hole in the back of this insulator here, as you can see, very very small, even without a huge
amount of actual sca
le. So you're never going to get a section of
TXL or normal automotive wiring through that, it's just not going to work. These generic milspec connectors on the
other hand, are. They also do require a back shell which screws
on if you want to use a boot on the back of them which in this case we're not so something
to be aware of. These are a nice middle of the road option. See these quite regularly used for the likes
of bulkhead connectors. The likes of Rywire which I've already mentioned,
Ryan
uses a lot of these on some of his professional harnesses as well so a nice step up
from either using a gromet through the firewall with no connector body at all, but not going
to the expense of a full autosport connector. Alright so we will move into our questions now
and if you do have any more, please feel free to keep asking, we'll see how many we can
get through. First question comes from Ryan who's asked,
hard resin vs. 2 part epoxy on rubber boots? I'm not quite sure on the angle with th
is
question and I'm not sure what you're referring to with hard resin. Essentially the only product I use is a 2 pot
epoxy and when it comes to the likes of these boots, again I'm not sure if this is what you're
referring to, I don't really call these a rubber boot, I'm not actually sure of the physical
construction of them but we call these heat moulded boot or a heat recoverable boot. These are available in 2 different styles,
they can be pre lined with epoxy which melts when it's recovered
down and this one
actually is, it's already got the epoxy inside of it, or you can get them without epoxy
in which case you would mix up a batch of your Resintech RT125 and then using a
syringe, you would install a small bead of that prior to recovery so yeah I'm sorry I'm
not sure what exact angle you were going with on that, if you get a chance you can clarify
and I'll see if I can give you a little bit more information. Alex the Bachelor has asked, considering the
price of the Autosport or
Souriau connectors, are Deustch industrial/HD/HDP something
you guys would recommend? I dont think i've ever seen them mentioned
in a course or webinar. HD and HDP is not a connector that I'm
personally familiar with, I don't know, I've never used their industrial range. Again, speaking out of turn because that's
not a product I'm familiar with, we've gone over obviously inside of this webinar,
the DT and DTP so that may be a crossover there. Dave's asked, when using factory sensors,
would
you always try and get rid of the factory connector, even at club level, and instead pot
the sensor and run a flying lead to a better style of connector? No absolutely not, I probably should be a little
bit more clear, it's not an essential and it comes down to that same thing of where are you
using the car, what's the level you're operating at? For an engine swap, a road car that's been modified,
club level racecar, absolutely not, that's a lot of work and expense to go to potting all of the
s
ensors and it really does also come down to is there a known issue with that sensor? So for example, the Toyota coil that we've
looked at and gone over extensively, in that case you might be on the fence. In a road car application where it's not
seeing the level of vibration that we'll see on a racetrack, might be absolutely fine, we
do know that that is a potential failure point with that particular product though so it's
something we do need to keep in mind. If on the other hand we're dealin
g with a sensor
that there's 100 million of them out there in the world, maybe the Honeywell pressure
sensor for example, we looked at the brass variant of that, the connector that comes
with those is not my favourite, it's not a great connector body but it's also pretty
well reliable and pretty well proven so in that instance, yes you could pot it but you're making
a lot more work for yourself, perhaps unecessarily and it's going to add time and
expense to your build so this is where you real
ly need to make your own decision
based on the application and based on your budget and how much time you're prepared
to put into it. There is no black and white answer and you must
do this. Alright that brings us to the end of our
questions. For any of our members watching this in our webinar
archive later on, please remember you can ask questions in the forum and I'll be happy to
answer them there. Thanks for watching and we'll see you all
next time.
Comments
Priceless content. One thing I always do is put a 2 pin Anderson connector on the car so it can be jump started and also used to charge a cars battery. So much easier and safer than jump leads . I’ve used the small grey ones and have still had no problems jump starting a car as long as you don’t do it for long periods . Also some audio connectors are very high quality and suitable for some applications , some RC car battery connectors are also high quality and often gold plated.
You have done an amazing job of this story. Something people will be watching for decades to come. Thank you.
Macon Georgia 87 supra targa 1jz non vvti single Garrett R154. What it do! 🤙 yall have been a game changer thank you 🫲
In the discussion about the autosport connector vs "milspec" connector density I think some context is missing. The autosport connectors were derived from mil-spec connectors and improved with added density and other autosport features. However, there are a wide variety of different "milspec" circular connectors with different densities and contact/insulation/cable sizes. There may be "milspec" 38999 connectors that also wouldn't work for your firewall bulkhead, while others will. And then there's "milspec" 5015 circular connectors that support much larger power wiring. To make this even more confusing, these traditional aerospace generated "milspecs" are now "AS" specs maintained by the Society of Automotive Engineers....the military has largely left the standards business. Add to this wrinkles like: commercial grade connectors that maybe are identical to a milspec connector except testing requirements or some other detail like plating....industrial connectors along those lines, and lastly, that there are also fiendishly expensive cutting edge high density "milspec" connectors for aerospace as well. It's enough to spin your head a few times.
Amphenol has a line of DT compatible connectors, AT/ATM/ATP, and they have keyed and colored variants.
I was working at DAF authorised service all connectors were TE conectivty Heavy Duty automotive connectors there is a wide range of connectors diifferent mounting styles i found it perfect for chassis harness they all are lever lock what makes them very reliable and they are quite cheap exception being sockets for modules but still they are llike 30$ + terminals but all connectors from this series uses same ones so when making a haness we need them in bulk anyway terminals are like 21c piece without bulk order comparing it to mil connetors in which just one housing can cost up to 400$ i found it perfect middle ground also the harness will have clean oem style for street cars it can be a huge deal to pass inspection
Hello I'm working on a car project I'm going to be using autosport connectors for the ecu and engine harness but I'm also going to be doing a chassis harness and since I'll be using autosport connectors for the ecu and engine harness should I keep with those for the chassis harness or should I use plain mil spec connectors.
would the mil spec connector be as good as a motorsport connector inside the chassis out of the elements and is the no way to add a boot to one. and if so would you have to machine a piece to add so that you could boot it
What's the most loved, and most HATED wiring connector you've used? - Taz. TIME STAMPS: 0:00 - Introduction 1:23 - Pro harness overview 3:46 - Considerations when choosing a connector 7:50 - Problems with factory connectors | Availability 9:26 - Connector suppliers 11:55 - Problems with factory connectors | Reliability 21:54 - Potting a sensor or actuator 28:15 - Choosing a connector | Autosport 32:48 - Choosing a connector | Deutsch 42:50 - Choosing a connector | TE Connectivity Composite 45:43 - Choosing a connector | Racespec aka 'Milspec' etc 49:32 - Questions
Definitely need to watch this a few more times. 😂 🇦🇺🤜🏼🤛🏼😎🍀☮️
Worked for TE Connectivity in the past making Deutsch DT Connectors; always wondered as a customer do you guys inspect your parts for things such as non-fills on the insulator walls or just trust the connector was made without any QA issues?
Can you please give examples of the make/series of connector you used for the Toyota 86 bulkhead that are “mil spec “ but accept OE harness as I have a similar issue on another vehicle Thanks in advance
Yo Yo
Connector experts is criminally overpriced. Most are like 20-30 times as much as sourcing them from electronics suppliers and they don't have any indication that they're genuine parts. I would stay away unless you have zero other options.