Dismembering the Mil-spec Connector
I had a customer ordered a Rywire Mil-spec engine wire harness for his EK9 a few months ago.
This piece of beauty cost about US$1200 or more with all the options it was specified for.
After delivery on this harness, and trying to figure out how he wants to place the engine harness through the firewall. Customer decided that he needs to shorten it so that it will work better, and look neater in his neatly tucked engine bay. 1 of the heat shrink also required to be changed to be straight, rather than at a 45 degrees angle.
The supplier for this harness, being half the world around and also very tied up with work was not going to be able to make it for the short timeline we had to get the car ready for a show. Thus, I offered some help on doing what I can to shorten it.
First, was to determine what the inside looked like and to see how to de-pin the Deutsch connector. So we had to slice through the original heat shrinks to expose the wires coming through the rear of the connector.
After which, there was a rubber boot which all the wires gone through that was epoxied in place into the connector. This was so that the connector will be waterproof and probably can be soaked in saltwater for years and still function. This really showed me the robustness of that said connector!
After which, I needed to get a proper Amphenol pin extraction tool so that I can remove the pins from the receptacle. Next would be to shorten the wires, put in the new heat shrinks, get new pins to crimp on the new wires, re-insert them into the receptacle, prepare epoxy to re-glue the boot to ensure waterproof, and then heatshrink the straight coverings back in place. Sounds easy doesn’t it?
Well…. not so it seems. If you look at the connector, almost every position is populated. From last count, there were 52 pins which I needed to extract.
Plus, the cost for the extraction tool, the pins, and specific crimping tool (which I already have, thank goodness) works out to be over US$150 on digikey.com before shipping!
Looks like I will need to discuss with the customer again on how we can do a work around on this harness…
Lesson learnt, if you want to do a wire-tuck on the car. Better be ready to do some extra work yourself and plan way in advance on everything electrical related!
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