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Pinning milspec connector

Professional Motorsport Wiring Harness Construction

Discussion and questions related to the course Professional Motorsport Wiring Harness Construction


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Hey guys,

I got to terminate a 61S connector while the branch was already recovered in dr25. As you can see from the pictures my service loops are a mess. Is the 222k163 boot too small for this 61S connector ? Or I just left to much exposed wires ?

Any tricks when you pin this kind of connector when the branch is already recovered ? I didn’t cut all the wires at once as you need more length depending where you are in the connector. I used 75mm on mosts wires though to leave room for service loops but I think it’s too much.

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So the boot is definitely too small for your chosen connector here. I have added a PDF for the moulded parts. When looking at the H dimension make sure it corresponds to the backshell diameter.

As for the lengths of the leads, if you hold up a terminal next to the shell and put the service loop in the wire where you want it to end up, you can judge pretty accurately where you need to cut it. I have also heard of people printing out one to one drawings of the connector and boot and doing the same thing that way. Unfortunately, I don't have any pictures of this at the moment so I hope my explanation is clear enough. Maybe someone else can chime in with a picture or a better explanation?

Attached Files

Thanks for the help Rob. Mostly what I tried to do here. I guess the 90 degree didn’t help me out.