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Discussion and questions related to the course Practical Motorsport Wiring - Club Level
= Resolved threads
Doing a harness with tefzel /32 where I planned to use AWG20 as the base for everything that doesn't require higher power than that size can handle.
I've run into some issues with the AWG 20 tefzel /32 outer insulation diameter, specified as 1.28 mm, being too small for either the terminal crimp itself or the smallest available seal.
Examples
* Standard GT150 3-pole connector for pressure sensors. Smallest seal is 15366022 that accepts 1.4-1.9 mm outer wire diameter while tefzel /32 AWG20 is 1.28 mm
* For both Bosch BAK connector for LSU 4.9 and VAG/FEP connector for Bosch/Hella accelerator pedals (DBW) the smallest terminal seems to be 1241380-2 or 1241381-2 that are specified for 0.5-1.0 mm2 copper wire area, 1.4 - 1.9 mm wire outer diameter (incl .insulation) so for this terminal the wire outer diameter is an issue as the tefzel /32 AWG20 is 1.28 mm
These are all very common connectors and but I haven't seen the issue mentioned before?
One solution is of course to use /16 for those connectors but that means I need more wire types.
What is the "industry standard"/best solution?
/Andreas
Other than stepping up the wire size, I have used short lengths of adhesive heat shrink under the seal area for small builds, or if you are doing a full build, either crimping a flying lead on instead, or adding RT215 or similar to the seal part of the connector.
