Engine Wiring Harness Replacement Options

[DaddyGlenn]

As of the last running, I don not have any issues with my engine wiring harness on my '78sc... but... for most wires, the insulation is hard and cracking. That can't be a good thing.

Does anyone know of a reasonably priced replacement option? Or is it realistic to consider building your own from scratch?

Thought? Ideas? Experiences?

[Hawkeye's-911T]

Hi Glenn

Not to hi-jack, but I have a 1970 & I am facing the same problems

Cheers
JB

[donporfi]

http://www.ynzyesterdaysparts.com/pdfs/Porsche.pdf

[PorscheGAL]

I had mine rebuilt by Jeff Bowlsby. He did a wonderful job on my 86' 911 harness! It was around $275.00.

Now, his site only list only 914s so you need to ask before you order or send it to him.

IReplacement Porsche 914 Wiring Harnesses

[DaddyGlenn]

Originally Posted by PorscheGAL

I had mine rebuilt by Jeff Bowlsby. He did a wonderful job on my 86' 911 harness! It was around $275.00.

Now, his site only list only 914s so you need to ask before you order or send it to him.

IReplacement Porsche 914 Wiring Harnesses

Now, that's what I'm talking about! Thanks Stephanie. I have sent Jeff an e-mail.

[Smoove1010]

DaddyGlenn,
Would you be kind enough to post the results of your investigation here? I'm looking at similar issues, and I entertained wrapping some wires in self-fusing tape in spots that look brittle, but that doesn't feel like a very Porschey solution.
Thanks,
GK

[DaddyGlenn]

GK, I'll keep this thread updated through the logical conclusion.

Got a response from Jeff. His focus is on 914 harnesses so he can't give me pricing until he sees my harness to see what it needs and how much the my 911 harness has in common with the 914 harnesses he does on a regular basis.

I'll strip the harness from my engine in the next few days and send it to him.

Once I hear back, I will post Jeff's response here.

[kerthunk]

I ordered up a bunch of wire in the OEM colors, some polyolefin shrink tubing and the proper connectors. With a proper wire diagram, it took me a few hours to put together a new harness for my '79. It really isn't that hard to do and if you still have your original harness, then getting the lengths correct is even easier. A couple of the bits are no longer available like the grommet that goes through the engine shroud to the alternator and the big block that bridges the rear engine tin. The biggest bummer is the quantities at which you have to order some of the stuff. So, I ordered up enough to make a couple of harnesses.

[DaddyGlenn]

Originally Posted by kerthunk

I ordered up a bunch of wire in the OEM colors, some polyolefin shrink tubing and the proper connectors. ...{snip}

Where did you source the connectors? And wire?

[kerthunk]

I got the 14-pin connector, female pins and reverse plug pins from Pelican. The wire and AMP connectors from eagle day (Eagle Day , PORSCHE, BMW, MERCEDES, AERO KITS, APPAREL, ACCESSORIES, PERFORMANCE). The polyolefin tubing, ring connectors and quick disconnects came from Waytek (Welcome to Waytek).

It was probably less than $75 in total to make a harness, with the Porsche connectors being the majority of the cost).

If you go this route, let me know as I have lots of remaining parts.

[DaddyGlenn]

Originally Posted by kerthunk

I got the 14-pin connector, female pins and reverse plug pins from Pelican. The wire and AMP connectors from eagle day (Eagle Day , PORSCHE, BMW, MERCEDES, AERO KITS, APPAREL, ACCESSORIES, PERFORMANCE). The polyolefin tubing, ring connectors and quick disconnects came from Waytek (Welcome to Waytek).

It was probably less than $75 in total to make a harness, with the Porsche connectors being the majority of the cost).

If you go this route, let me know as I have lots of remaining parts.

Thanks John. Any special skills or tools needed?

[kerthunk]

Not really any special skills..."puzzle solving" maybe? A multimeter, wire strippers, a decent crimper and a soldering iron. The only bits that need to be soldered are the terminals for the 14 pin connector and for the reverse light switch. The multimeter is really only used as a continuity tester to help verify all of the connections. There are no resistors, capacitors or anything like that in there, just simple wires connecting stuff to other stuff. Just be sure to use the proper wire gauges for each run.

If you use the factory electrical schematic, it even gives you all the wire colors and proper gauge to use:

http://www.pelicanparts.com/911/911_Parts/Electrical/911_electrical_78SC_USA.pdf

[DaddyGlenn]

Originally Posted by kerthunk

I got the 14-pin connector, female pins and reverse plug pins from Pelican. The wire and AMP connectors from eagle day (Eagle Day , PORSCHE, BMW, MERCEDES, AERO KITS, APPAREL, ACCESSORIES, PERFORMANCE). The polyolefin tubing, ring connectors and quick disconnects came from Waytek (Welcome to Waytek).

It was probably less than $75 in total to make a harness, with the Porsche connectors being the majority of the cost).

If you go this route, let me know as I have lots of remaining parts.

Sent you a PM

[Chuck.H]

+1 on Waytek, a great company to get wiring stuff from. I really like using the non-insulated crimps, and covering it with shrink wrap. Their welded gap non-insulated crimps really grip tight - I use the single ones and put both wires into one crimp where possible.

Chuck.H
'89 TurboLookTarga, 346k miles

[kerthunk]

Originally Posted by Chuck.H

+1 on Waytek, a great company to get wiring stuff from. I really like using the non-insulated crimps, and covering it with shrink wrap. Their welded gap non-insulated crimps really grip tight - I use the single ones and put both wires into one crimp where possible.

Chuck.H
'89 TurboLookTarga, 346k miles

I also use the non-insulated crimps and cover them in shrink wrap. I'm not having pink, blue and yellow connectors decorating my engine bay! This is a Porsche, not a birthday party at McDonalds!

[timmy2]

I'm building them now. 3 done and a few more on their way to me.
Building SC and Mid Year Engine Harnesses

[skinnerd]

Always wondered about this group?
The work looks 1st rate....but likely expensive.

Kabelkonfektion Wocheslander - The high-quality wiring harness for your classic car

[timmy2]

Posted this in the classifieds, in my thread that is linked above.
I'm making the rubber parts that are NLA for the harnesses.
For sale as a set if you are rebuilding your own.
(Reverse connector boot, CDI connector boot, Engine tin grommet, Fan shroud to Alternator grommet)

[ozracer]

why did you build a new harness was it to eliminate any electrical gremlins because of the age of the car?

PS looks fantastic I amy consider this when I drop my engine next it seems like a good idea on a car I use on a regular basis.

[timmy2]

Safety...
The wire insulation of the harnesses ages poorly due to the heating cooling cycles.
If you try to twist or move wires, the insulation cracks and falls off exposing the live wires.
One harness I was sent to rebuild was really crispy and had bare wire in numerous locations.