How does one "make" ignition wires?
 

I see these red ignition wires in pics of peoples motors and I assume they are somehow home made. Am I correct? I'd like to do a tune up of my 964 before winter and the cost of a set of (twelve!) ignition wires has me staggered. So how do I take my existing connectors and replace the wire? What parts will I need? Where can I get the best raw wire from? I haven't really screwed up anything big on my car in weeks and I'm itchin' to try. Are special tools involved? I understand the wire somehow "screws" into the connectors - but I'd like to have more of a clue before I go tearing apart my existing (expensive) wires.

I made a set for my Ferrari by first buying a set of pre-made ignition wires (red) from Taylor wires. Then I used a crimper to crimp on the connector after cutting wires to the correct length.

For the Porsche, I opted to buy a ready made set in Red from a well known supplier. I thought it was too hard to remove the old connectors and reuse them. And buying new set of connectors would cost just the same amount of money as a new set of wires.

I got a set of magnecor 8mm for my 911 and cut it and installed the end connectors myself.

Doing it this way came out much cheaper.

I just recently did this on my RSR clone. I used solid core wire from Moroso, crimp on clips from NAPA and Porsche OEM plug connectors. Very simple and easy.

So you got crimp on connectors for the distributor end from Napa? And Porsche dealers still stock the spark plug end?

Okay, I'm game. I checked Summit Racing and they sell raw ignition wire in sizes from 7mm to 10.4mm. It seems to range in price from just over a dollar per foot to big $$$. Either way, if all I need is the wire and some crimp connectors, then making wires will be MUCH cheaper than buying a whole new set. So what do I need to know? Is 10.4mm wire worth the price? Are some brands or features better than others?

I think the stock is 7 mm, why go bigger?

8mm will be fine with a stock ignition system, anything much larger is a pain to get in the cap.

Invest in a nice set of terminal crimpers. Does the job faster and better, and will pay for themselves if you make a few wire sets for other cars.

Win

once you add new plug connectors to the picture, @ $20 each, you don't save a bundle, just a bit.

You can reuse the plug connectors if you really need to save $$$. I don't know what the lifespan of them is, though, and whether or not that is a good idea. I have reused them (years ago) when I just did not have the money for a complete set and the car ran fine, but the next time I replace the wires I bought a pre-assembled set.

they need to be checked for proper resistance with an ohmmeter, usually around 3K ohm. occasionally they get a pinhole burned thru the casing which can spark to ground.

There is a great Beru PDF booklet that demonstrates the construction steps and details of the M3 threaded stud used on Mercedes and Porsche wires available for download here:

http://www.beru.com/download/produkte/stecker-TI05_e.pdf

It is 2.2 MB, and a rather painful download at 28.8 bps from a hospital room dial-up line ... compared to DSL!

If your ignition cables are putting on a 'light show' at night or in a darkened garage ... it is time to replace the wire between the replaceable connectors!

Warren - I hope you are doing ok (?)

Nice link Warren, hope your doing OK!? For hospital money, dial-up is a crime:)

So which part no.'s are correct for Porsche on that .pdf file?